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Flexo Sustainable : Year-End 2013
Organization Retention Other Human Resource Elements • Environmental • Compliance Tax Regulatory • Product Liability • Business Risks The end result is an easy to follow heat map that reflects current risks, scored in two tiers. Finally, Flint utilizes what it calls the Integrity Assurance Pol- icy “to report issues in a safe and secure environment.” T his enables employees to raise concerns in a confidential setting. SOCIAL Flint’s large workforce is the driving motivator behind efforts to become a greener company, as they too inhabit the Earth that is being preserved. The four areas it focuses on are: • Leadership Develop employees to their maximum capabilities Ensure employees are properly placed in their posi- tions Plan a line of succession and line of future talent • Team and individual performance Regular evaluation of goals and progress Reward system based on job specific criteria • Employee engagement Recognition and praise of success Effective and open lines of communication Regular surveys of employee satisfaction • Effective organizations Clear roles and expectations of each level Avoiding a one size fits all approach to leadership and structure The company ’s complex supply chain—including more than 2,500 raw material suppliers—is another key area to improve efficiencies. “ T he key to understanding the overall sustainability impact in the chain needs to include the impact we ‘receive’ with the purchased raw materials from our sup- pliers,” the report states. In the most recent survey of suppli- ers, 86 percent reported having an environmental policy and 56.5 percent a sustainability policy; 15 percent were said to be working on one. Safety is also of paramount importance. Through various safety initiatives, the company has reduced its total injury rate per 200,000 hours worked to less than one and a 64 percent decrease in the past five years. To learn more about Flint’s sustainability efforts and to obtain a copy of the company ’s Sustainability Report 2013, visit www.flintgrp.com/en/company/sustainabili- ty-Report-2013.php. n Using environmentally responsible practices, Flint Group promotes energy efficiency by evaluating new technology, optimising current processes and implementing programmes that focus on improvements in reducing our operational use of fossil fuels and electricity. In the last several years, Flint Group has implemented many projects and process improvements that have resulted in direct reduction of carbon dioxide–equivalent emissions. Some of our energy–saving initiatives and projects to conserve valuable resources include: Energy monitoring control systems • Fully automated, online energy consumption systems used at large facilities to help visualise, understand and better manage energy consumption • Provision of an alarm system for leakages or high peaks of energy demands • Existing systems have resulted in building and tank farm heating reduction by 10% and overall electricity consumption reduction of 5%. ￼ Digital monitoring of energy usage For several years we have been using a digital monitoring and measuring system and each year we see energy reductions. The main advantage is our ability to visualise the usage and the clear relationship between process steps and consumption. This has been particularly evident in the first few years, when we have reduced energy consumption by double digit percentages. One important step in the project has been the implementation of limits during operations and also during the weekend. If necessary, automatic e-mails are sent out with an alarm that makes it very easy to recognise any kind of leakage, e.g. for compressed air. Because of its monitoring system and information flow in real time, we see the effect of energy consumption and can use this process to optimise a facility. FLINT GROUP SUSTAINABILITY REPORT 2013 FLINT GROUP SUSTAINABILITY REPORT 2013 Improvements • Replacement of older fluorescent lights with T8 lights. T8 fluorescent lights are more energy efficient than older fluorescent systems. In addition, they run on less mercury than older bulbs and have more consistent light output, are quieter and produce less heat than standard fluorescent tubes. • Replacement of standard fluorescent ballasts with energy-efficient magnetic ballasts or electronic ballasts • Upgrading equipment with higher efficiency units that consume less power • Motion–sensing lighting systems in warehouses to reduce electrical consumption without employee intervention • Boiler upgrades • Installed boiler units called “economisers” that preheat water for steam generation using heat from boiler flue • Condensate return from steam lines that allow reuse of heated water resource • Elimination of condensed air and steam leaks • Production processing optimisation, reducing per-unit energy consumption • Supply chain efficiency improvements • Selection of freight carriers who participate in various programmes, such as the US EPA SmartWay • Transport Partnership for inbound materials and outbound products to customers • Internal transport tractor fleet equipped with auxiliary power units (APU) to avoid main engine idling • Improved packaging to eliminate unnecessary weight and volume of material being shipped • Maximise weight and volumes of incoming materials resulting in fewer numbers of inbound shipments. 24 <1xperminute Committed to the effective and efficient use of energy and water Committed to the effective and efficient use of energy and water Flint Group is committed to the effective and efficient use of energy and water throughout our operations and we are committed to actively conserving energy and water throughout the life cycle of our products. Information Amount and Performance per minute ElectricityCO(Tonnes)JAN11FEB11MAR11APR11MAY11JUN11JUL11AUG11SEP11OCT11NOV11DEC11JAN12FEB12MAR12APR12MAY12JUN12JUL12AUG12SEP12OCT12NOV12DEC12 0 3,000 6,000 9,000 12,000 15,000 2ElectricityUsageinGJ 60,000 80,000 100,000 JANFEBMARAPRMAYJUNJULAUGSEPOCTNOVDEC - 2012 - 2011 Transient voltage Where applicable, the larger sites have added TVSS (Transient Voltage Surge Suppressors). TVSSs mount to the main or sub-panel and remain passive until a voltage surge hits the panel. Then within a nanosecond clamps the excess voltage to ground. Excess voltage, if left unchecked, creates heat which increases resistance and leads to poor mechanical operation. TVSSs flat–line this voltage, reduce energy consumption by 15%, reduce equipment maintenance costs and repairs and will save sensitive equipment from dangerous voltage transients. The formula is simple. Heat wastes energy. Removing transients reduces operating temperature and premature mechanical breakdowns=energy cost savings and mechanical cost avoidance. Lighting Reducing energy is only one reason why we looked deeply into our lighting package(s). EPACT (US Energy Policy Act of 2005) was a bill signed into law in July 2005. This Act promotes energy conservation through changes in lighting requirements: discontinuing lighting systems and offering tax incentives to consumers who make lighting improvements. Where applicable, many plants have upgraded their lighting. One specific analysis at our Batavia, Illinois, plant identified wasted energy through poor wiring and older fixtures. Inefficient ballasts with steel design created large amounts of heat and noise, increasing HVAC demand and causing premature lamp failure. The study also identified fixtures that were daisy–chained together, which is dangerous and also a heavy drag on energy. New conduit and new fluorescent fixtures with parabolic reflectors, air ventilation holes and black emissive coatings on the ballasts were installed. This system delivered more light using less wattage. The upgrade reduced heat dissipation, electrical drain, HVAC demand, and ultimately, nearly 50% in electricity costs. Emissions from Electricity Electricity Usage 8 Sustainable FLEXO YEAR END 2013 www.flexomag.com
Earth Day 2014