Designing Out Waste

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Designing Out Waste

• Mark Shayler and Leigh Holloway
• eco3

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Designing Out Waste

• Eco-design. Why, What and How?
• Focus on WEEE and RoHS
• Disassembly Exercise
• Support for Designing Out Waste
• Peter Gafney

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EcoDesignWhy, What and How?
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Why the Environment?
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Environmental Concerns

• Growing Concern
• Environmental damage
• Stricter regulations
• Customer requirements
• Public perceptions
• Changes in business practice
• Win win situations

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Changes in Business Strategies
Environmental Compliance
Environmental Risk Assessment
Sustainable Business Strategies
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Why Products ?
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A product is a symbol of a companys
capabilities. It is a result of all the decisions
made before, during and after the design phase
Philips
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Quality
Innovative
High Tech
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Increasingly the environmental performance of
products will also say something about the
companies that make them
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Why should I look at EcoDesign?
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What is Driving this Shift?

• Legislation
• Waste disposal and clean-up costs
• Increasing efficiency
• Environmental management systems
• Producer responsibility
• Customer requirements
• Supply chain issues

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Legislation!
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Legislation

• Product-based
• Packaging Regs. 1997
• Packaging Essential Requirements 1998
• Fridge and freezer recycling (removal of CFCs)
  2002
• End-of-life Vehicles (ELV) 2000
• Waste Electrical Electronic Equipment RoHS
  Directives 2003
• Banning of certain substances to landfill
• Recovery of batteries etc.

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Packaging Regs. Essential Requirements

• Came into force 31 May 1998
• Require
• Minimal packaging
• Noxious hazardous substances minimised
• Packaging must be recoverable
• Limits on heavy metal content
• Applies to ALL companies regardless of size and
  turnover

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End of Life Vehicles (ELV)

• Requires the recovery and recycling of vehicles
  at the end of their life.
• Original manufacturer is ultimately responsible
• Legislation came into force in the UK 2003
• Material restrictions
• 2005 European standards for recovery and
  recyclability
• 2007 Take back of ALL ELVs

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Waste Electrical and Electronic Equipment (WEEE)
RoHS

• UK legislation will be in place by late 2004
• Forces the recovery and recycling of electrical
  and electronic equipment
• Restricts certain substances (RoHS)
• Producers are to pay for collection and recovery
• Directive implies the benefits of using ecodesign
  principles

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EcoDesign of Energy Using Products

• Similar to essential requirements in packaging
• Requirement to display a logo showing conformity
• Require a high level of environmental
  protection
• Specific design requirements such as disassembly,
  recyclability, energy efficiency to be used where
  appropriate and feasible.
• Avoid the undue use of devices, components
  materials or substances which present a threat to
  the environment..

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Supply Chain

• Large companies are taking on the idea of
  corporate responsibility
• EMSs are being extended to cover products
• (EMAS II and ISO 14040 14060)
• Companies are auditing their suppliers for
  environmental compliance
• Many organisations are developing their own
  design guidelines and material restrictions and
  as a supplier you will need to be able to meet
  these
• Some customers are even offering price incentives
  for eco-friendly products

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What is EcoDesign?
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Why Focus on Products?

• 93 of production materials are never used in the
  final product
• 80 of products are discarded after a single use
• 99 of materials used are discarded in the first
  six weeks

Source Factor 4
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Up to 80 of a products financial costs are set
at the design phase
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Materials used in product manufacture all have
some sort of environmental impact

• Use materials with less impact
• Reduce materials used
• Make use of recyclate
• Use renewables

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Processing uses energy and produces waste and
emissions

• Use efficient processing routes
• Recycle waste materials
• Use low energy options
• Avoid the use of hazardous materials

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A products use can have very important effects
on its overall environmental impact

• Reduce energy consumption
• Reduce resource consumption
• Increase durability
• Design for maintenance/upgrade
• Use alternative energy sources
• Reduce weight?

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Design changes can increase the economic
feasibility of recovery and recycling
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Every product has an ecological footprint
They are just different sizes and shapes
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Applied EcoDesign How to do it .. successfully!
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Varian Medical Systems

• One-off 25K investment
• Component costs reduced by
• 14 per annum
• Component count reduced by 65
• Fasteners used reduced by 29
• Assembly time reduced by 27
• Resulted in a 145k net
• saving in the first year

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Continental Teves UK Ltd

• Leading Supplier of braking systems to UK and
  European automotive industry.
• Brake calliper redesign
• 26 reduction in weight
• 42 reduction in production time
• 62 reduction in machining time and 420 tonnes of
  metal per year saved
• Over 120k net saving per annum

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Fulleon Ltd
Savings
Materials costs reduced by 11 - 27550 Labour
costs reduced by 34 - 65100
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Conclusions

• A new business agenda is emerging
• Much more focus on products
• Focus may drive innovation
• Ecodesign and innovation isnt rocket science

EcoDesign
Good Design
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Focus on WEEE and RoHS
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Background to the Directives

• Rapid innovation and increasingly short product
  cycles have lead to huge volumes of relatively
  new products being discarded
• WEEE represents a major source of organic
  contaminants and heavy metals which are
  potentially harmful to the environment
• Potentially recyclable materials are being
  landfilled
• Inefficient use of Europes remaining landfill
  capacity

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Broad Objectives

• The WEEE Directive is aimed at
• reducing electrical waste, increasing recovery
  and recycling and minimising environmental impact
• improving environmental performance of all
  operators involved in the life cycle of EEE

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What is a Producer?

• producer means any person who, irrespective of
  selling technique used, including by means of
  distance communication
• 1. Manufactures and sells his own brand
• 2. Resells under his own brand
• 3. Imports or exports

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What items are covered by WEEE?

• All equipment that is dependent on electrical
  currents or electromagnetic fields
• although certain thresholds apply only equipment
  with a voltage rating not exceeding 1000V AC and
  1500V DC is included

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10 indicative categories

• 1. Large household appliances
• 2. Small household appliances
• 3. IT and telecoms equipment
• 4. Consumer equipment
• 5. Lighting equipment
• 6. Electrical and electronic tools
• 7. Toys, leisure sports
• 8. Medical devices
• 9. Monitoring devices
• 10. Auto-dispensing machines (vending machines,
  cash machines, ticket machines)
• Exempt from RoHS requirements for now

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Key Requirements of WEEE

• Set targets for the recovery and recycling of
  WEEE according according to category of product
• Large household and automatic dispensers (1,10)
  80/75
• IT and consumer (3,4) 75/65
• Others 70/50
• Gas discharge lamps 80 (recycled
• No target for medical equipment (8)
• Targets to met by 31 December 2006

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Targets
Category Description Recovery Recycling
1 large household appliances 80 75
2 small household appliances 70 50
3 IT and telecoms equipment 75 65
4 consumer equipment 75 65
5 lighting equipment 70 50
6 electrical and electronic tools 70 50
7 toys leisure sports 70 50
8 medical devices no target no target
9 monitoring devices 70 50
10 auto-dispensing machines (vending machines, cash machines, ticket machines). 80 75
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Key Requirements of WEEE

• Collection facilities to be in place from 13
  August 2005
• Kerbside, bring schemes, retailer take-back
• Consumers to return WEEE free of charge
• No absolute requirement to enforce separate
  segregation of WEEE
• A target collection of 4kg per head of population
  to be achieved by 2006
• A new target will be established by 31 December
  2008

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Key Requirements of WEEE

• By August 2005 producers should provide financing
  for the collection, treatment, recovery and
  environmentally sound disposal of WEEE from
  private household deposited at collection
  facilities
• Products placed on the market after 2005
  producers should be responsible for financing
  waste relating to their own products

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Key Requirements of WEEE

• WEEE put on the market before 13 August 2005 or
  historic waste is to be financed
  proportionately by producers existing in the
  relevant market when the respective costs occur
• For a transitional period of 8-10 years producers
  can show the costs incurred in the disposal of
  WEEE

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Key Requirements of WEEE

• From August 2005 B2B producers should finance the
  collection and treatment of WEEE
• For historic B2B waste the end-user may be
  partially or wholly responsible for the financing

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Requirements of WEEE

• Producers or third parties acting on their behalf
  to set up treatment facilities
• Carried out by regulated operators according to
  standards
• Treatment/removal of
• PCBs over 10cm2, LCDs over 100cm2, toner
  cartridges, batteries, CRTs

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Timescales

• Common Position text - Dec. 2001
• European Parliament Second Reading - April 2002
• Conciliation process - completed Oct. 2002
• Adoption of Directives - Late 2002
• Publication - 13 February 2003
• Member States Transposition by 13 August 2004
• Producer Responsibility - 13 August 2005
• Substance Ban (RoHS) - July 2006
• Meeting Recycling Targets - 31 December 2006

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The Restriction of Hazardous Substances Directive
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RoHS Directive

• A Single Market Directive on the restriction of
  certain hazardous materials
• Seeks to reduce the environmental impact of WEEE
  by restricting the use of certain hazardous
  substances during manufacture
• Complementary to the WEEE Directive

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What is Covered by RoHS?

• From 1st July 2006, the following are banned -
  lead, mercury, cadmium, hexavalent chromium,
  polybrominated biphenyls and polybrominated
  diphenyl ethers
• Some exemptions exist

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Scope

• All equipment dependent on electrical currents or
  electromagnetic fields
• Eight broad categories, plus electric light bulbs
• All products in the WEEE Directive except
• Medical equipment and monitoring and control
  equipment

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Annex Exemptions I

• Mercury (in some lighting applications)
• Lead in the glass of cathode ray tubes,
  electronic components and fluorescent tubes
• Lead in certain steel, aluminium and copper alloys

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Annex Exemptions II

• Lead in high melting temperature type solders
• (Until 2010) lead in solders for servers, storage
  and array systems
• Lead in solders for network infrastructure
  equipment

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Annex Exemptions III

• Lead in electronic ceramic parts
• Cadmium plating
• Hexavalent chromium in absorption refrigerators

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Proposed Limits

• It is likely that limits will be set for RoHS
  substance
• The current proposals are for percentage by
  weight of homogenous material or discreet
  component
• Cadmium 0.01
• Others 0.1

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Servicing of Older Equipment

• Article 2.3
• This Directive does not apply to spare parts for
  the repair, or to the re-use, of electrical and
  electronic equipment put on the market before 1
  July 2006

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Arms and Munitions

• Article 2.3 of the WEEE Directive
• Equipment which is connected with the protection
  of the essential interests of the security of
  Member States, arms, munitions and war material
  shall be excluded from this Directive.

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Future Review

• By 1/2005 proposals to include equipment in
  categories 8 (medical) and 9 (monitoring
  equipment) of the WEEE Directive
• Evaluation of the implications for
• Deca BDE this is now covered
• Mercury in straight fluorescent lamps for special
  purposes
• Lead in solders for servers etc.
• Light bulbs

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Timetable

• Conciliation concluded October 2002
• Final text approved December 2002
• Publication in OJ January 2003
• UK legislation in place July 2004
• Substance bans 1st July 2006

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Implications for Design

• WEEE
• Weight
• Disassembly
• Recyclability
• Removal of items requiring pre-treatment
• Labelling
• Wider re-design opportunities

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Implications for Design

• RoHS
• Identification and replacement of proscribed
  substances
• Design implications product
• Design implications process
• Compatibility between alternative solders
• Functionality is it over-egged?

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e3 toolkit

• Compliance check
• Obligation calculation
• Training materials

• Interactive guides
• Lead-free section
• Quizzes

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e3 toolkit

• Video industry views
• Materials declaration forms
• Supply-chain actions

• Where to find RoHS proscribed materials
• Alternatives
• DIY testing kits

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Disassembly Exercise
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Group Work

• Electronics
• Take them apart carefully
• Examine
• Packaging
• Fixings
• Materials
• Labelling
• Ease of disassembly
• Opportunities for
• Simplification
• Modularity
• Reuse
• Servicing
• Ease of compliance with WEEE/RoHS?

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Group Work

• Other products focus on packaging
• Type and mix of materials
• Does it do its job?
• Could it be simplified?
• Implications for Essential Requirements and
  Recovery costs?
• Feedback

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