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SYSTAIN CONSULTING
THEKEY.TO ACADEMY
The Carbon Footprint of Textiles Norbert Jungmichel, Systain Consulting
Berlin | July 5th 2010
Systain Consulting – more than 10 years of passion for sustainability
Systain Consulting
Systain Consulting is an experienced CSR consultancy. Together with our clients, we develop tailor-made and pragmatic solutions for sustainable management – with main focus on the supply chain. Our clients range from brands, retailers, importers and producers.
The Systain team offers: -
Systematic solutions for sustainability Comprehensive business know-how Performance-oriented consultancy Headquarter in Hamburg and offices in the main production markets 25 employees of various nationalities in 4 countries July 5th 2010
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Systain worldwide Hamburg
Hong Kong Schwäbisch Gmünd
Istanbul Dhaka
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Carbon Emissions are faced an increasing awareness among consumers
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Relevance of the topic CO2 for several product groups today and in the future Growth rate Furniture Fruits and Vegetables Frozen Food Fast-food and Coffee Shops Fashion, Clothes and Shoes Chemist and Hygiene Store Creamery Products Toys Do-It-Yourself Supplies Books and Newspapers Over-The-Counter Drugs Today
Soft Drinks
Future
Confectionary
Survey among 1.011 consumers in Germany, carried out by Sempora, Sept. 2007 Systain Consulting 2009
July 5th 2010
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Patagonia (U.S.): information about environmental impact of textiles
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Information about the carbon footprint Carbon footprint related to the weight of the textile Information about energy consumption, waste etc. Trace & tracking for consumers Regular T-Shirt: CO2 equals eight times the weight of the shirt www.patagonia.com
July 5th 2010
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Fossile fuels cause CO2-emissions 1)
Bestandteile: 1 Atom Kohlenstoff (C), 2 Atome Sauerstoff (O = ½O2)
2)
Summenformel:
3)
Strukturformel:
4)
Molare Massen: C = 12 g/Mol, ½O2 = 16 g/Mol, CO2 = 44 g/Mol
5)
Aus 4) ergibt sich für CO2 ein Anteilsverhältnis von
6)
Der Kohlenstoffanteil in fossilen Brennstoffen liegt bei ca. 85%
7)
1 kg fossilen Brennstoff = ca. 850 g Kohlenstoff (C) Dichte von verschiedenen fossilen Brennstoffen:
CO2
C O
O
1 : 1,3 : 3,67
(C : ½O2 : CO2)
7.1) Dieselkraftstoff = ca. 845 g /Liter 7.2) Ottokraftstoff = ca. 750 g /Liter 7.3) Schweröl = ca. 1.000 g/Liter Beispielrechnung für Diesel -
Ein Liter Diesel hat eine Masse von ca. 845 g (siehe 7.1)
-
Da der Masseanteil von Kohlenstoff in fossilen Brennstoffen bei ca. 85% liegt (siehe 6), enthält ein Liter Diesel ca. 718,25 g Kohlenstoff.
-
Entsprechend dem unter 4) ermittelten Kohlenstoffanteil für CO2 entstehen bei vollständiger Oxidation von einem Liter Diesel: 718,25 g C * 3,67 g CO2/g C=
2,6 kg CO2/ Liter Diesel
*für Diesel (ohne Emissionen bei Förderung und Raffinierung * 1 Mol = 6.0221367 * 10-23 Teilchen (Avogadrosche Zahl) ** Dieser Wert schwankt mit der Kraftstoffdichte July 5th 2010
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The Carbon Footprint indicates all greenhouse gas emissions along the whole life-cycle
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July 5th 2010
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The journey of a longshirt: from the cotton field in the U.S. via the factory in Bangladesh to the consumer in Germany
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Figure: google
Long shirt ‚Boysen’s’, ¾ sleeve, white, 100% cotton, Size 40-42, Net weight 222 grams
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July 5th 2010
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Carbon Footprint of the white longshirt: 10.75 kg CO2e, 50 times the net-weight Disposal 0.25 kg 2%
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Cotton Cultivation 1.27 kg 12%
Use-Phase 3.30 kg 31% Manufacture 3.00 kg 28% Packaging 0.24 kg 2% Catalogue 1.53 kg 14%
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Transports 0.29 kg Distribution 3% 0.87 kg 8%
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N2O-gases are linked to cotton growing and have an almost 300-time larger effect than CO2
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The Carbon Footprint regarding cotton growing incl. ginning makes up 1,27 kg CO2e. Indicated by generic secondary data due to data gaps for cotton growing. Almost half of it caused by direct and indirect nitrous oxide emissions (N2O), which has a Global Warming Potential (GWP) of 298 relative to CO2
N2O 45%
CO2 53%
CH4 2%
The level of uncertainties is quite high: - Direct emissions of N2O depends on temperature, soil structure, the use of fertilizer, water etc. - Production of fertilizers – no data outside the western hemisphere available - Land use Change? - Carbon sequestration by the cotton?
July 5th 2010
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Manufacture implies an emission-level of 3.0 kg CO2e per functional unit
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1,20
1.02 kg
0.98 kg
1,00
0.88 kg
CO2e (in kg)
0,80
0,60
0,40
0,20
CO2e-emissions in the production spinning – sewing/RMG (excl. transportation)
0.12 kg
0,00 Spinn ing
Knit ting
D yeing
RMG
Approx. 2/3 of the carbon emissions are caused by electricity, 1/3 by heating processes A major part of the electricity is generated on site (gas generators) High proportion of natural gas as source of energy Production of a dark longshirt (same size): 3.41 kg CO2e Systain Consulting 2010
July 5th 2010
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0.87 kg CO2e are being emitted due to distribution processes, more than half result from returns
2nd delivery 0.11 kg
2nd pick-up customer 0.01 kg
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Warehousing 0.11 kg
2nd warehousing 0.05 kg
Delivery 0.28 kg Transport return 0.29 kg
Pick-up customer 0.01 kg Return by customer 0.01 kg Systain Consulting 2009
July 5th 2010
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Consumers can contribute significantly to reduce the Product Carbon Footprint
Carbon Footprint for use phase (55 laundries)
12.0 kg
Scenario 1: base scenario with shared usage of dryer and iron according to the statistical average 10.0 kg
Carbon Footprint (in kg CO2e)
Scenario 2: permanent usage of dryer and iron after each laundry 8.0 kg
6.0 kg
4.0 kg
2.0 kg
Washing machine
dryer
Stock Germany
95%
36%
Loading capacity (average)
5 kg
6 kg
Use of loading volume (average)
73%
75%
Mass per loading (in kg)
3.65
4.50
Use per wash cycle
100%
17%
Average energy consumption
0.80 kWh
3.30 kWh
Assumptions of the carbon footprint calculations for the use phase 0.0 kg Base scenario: ØHousehold D
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Scenario: permanent use of dryer and pressing iron
Washing machine Water supply Pressing iron
Washing agent Dryer
July 5th 2010
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Options for reducing carbon emissions can be identified – example of energy efficient devices
Household devices with an improved level of energy efficiency may reduce the Carbon Footprint in use phase by one third, compared to the household stock. The Carbon Footprint in the use-phase is further determined by: Washing temperature Actual loading of appliances
A washing temperature of 40°C instead of 60°C reduces the Carbon Footprint of the usephase by 45%, 30°C instead of 40°C by 40%. Washing machine Water supply Pressing iron
July 5th 2010
Washing agent Dryer
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In total, three textiles have been evaluated
Long shirt ¾ sleeve, white 100% cotton
Sweat-jacket with hood, fuchsia 100% cotton (‘Cotton made in Africa’)
Jacket for kids, red 100% Acrylic
Size 40-42 Net weight 222 grams Cotton from U.S. Production in Bangladesh Offered by OTTO
Size 40 Net weight 446 grams Cotton from Benin Production in Turkey Offered by BAUR
Size 152-158 Net weight 266 grams Acrylic from China Production in Bangladesh Offered by OTTO
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Three products - three Footprints – and lots of information
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Product Carbon Footprint (in kg CO2e)
16.0 13.42 kg
14.0 12.0
13.67 kg
10.75 kg
10.0 8.0 Disposal Use-Phase Packaging Catalogue Distribution Transportation Manufacture Raw Materials
6.0 4.0 2.0 0.0 Long-Shirt white
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Sweat-Jacket fuchsia
Acrylic Children Jacket red July 5th 2010
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Energy efficiency and national grid factor reduce the carbon footprint in manufacture in Turkey
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2.5
Carbon Footprint (in kg CO2e)
2.21 kg 2.0
1.5 1.07 kg 1.0
0.5 0.24 kg
0.20 kg 0.0 Spinning
Knitting
Dyeing
CO2e-emissions in the production spinning - RMG (excl. transportation)
RMG
40% less GHG-emissions for manufacture compared to the longshirt produced in Bangladesh (mass equivalence) But 90% more GHG-emissions for dyeing due to: waste water treatment, color intensity, thickness of knit-fabric, energy sources (natural gas + lignite) Dyeing I: exclusive use of natural gas: 1.43 kg CO2e; exclusive use of lignite: 2.30 kg CO2e Dyeing II: elasticity of carbon footprint due to volatile production – doubling emissions per output Systain Consulting 2010
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Cooling and Lighting have a significant quantity of electricity consumption in a garment factory
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Analysis of electrical equipment
17% 41%
Machinery W ashing Unit 20%
Cooling (fans and AC) Lighting
22% Percentage of electrical devices, clustered by electrical load (example garm,ent factory in Bangladesh – acrylic jacket)
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Only low reflection of light by the ceiling
Inadequate reflectors
Tubes with less Watt would also be appropriate
Main switch instead of separate lights switchers
Too much tubes for lighting
Use of magnetic ballasts instead of electronic ones
Dark, light absorbing ceiling, walls and floors
July 5th 2010
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Carbon Footprint results in transparency and raising awareness
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Capabilities of the PCF: Creating Transparency Identification of Hot-Spots Determining alternatives Addressing carbon emissions in the supply chain Addressing carbon emissions in emerging markets Awareness Raising Using for management instruments
Incapabilities of the PCF: Not an exclusive eco-indicator No comparison by a CO2-label No exact, universal result
Linking CO2-emissions with energy costs is a key success factor Systain Consulting 2010
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Four steps for a systematic approach 1. Orientation
2. Transparency
3. Strategy
4. Implementation
• Are there regulations that may affect my business / -partners? • What are expectations from our costumers, investors, the public? • … • • • •
What is the carbon footprint of my company? Where can I find hot-spots for energy consumption? How much are the energy costs? …
• • • •
What measures may reduce the energy consumption? What are short-term measures that can be taken immadiately? What are my investment costs? …
• • • •
How can I implement the defined measures in existing processes? Who has to do what? How shall I communicate these measures? … July 5th 2010
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Systain Consulting GmbH Norbert Jungmichel Wandsbeker Str. 13a 22179 Hamburg
[email protected] T. +49 40 6461 8459 F. +49 40 6461 6666
www.systain.com
Systain Consulting 2009
July 5th 2010 09.07.2010
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