Interface’s Sustainable Carpets: Zero Waste
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Transcript of Interface’s Sustainable Carpets: Zero Waste
“ What is common to the greatest number has the least care bestowed upon it “ - Aristotle
THE WORLD’S LEADING MODULAR CARPET COMPANY
INTERFACE INC. Business
• Commercial Carpet
• 40 -Year history
• Size: $ 1.2 Billion
• Where: Global
• Footprint:
• 6 Manufacturing
• 37 Offices
INTERFACE ( A Global Company)
Asia-Pacific
15%
Europe 23%
Americas 62%
MARKET SEGMENTATION
HOSPITALITY
EDUCATION
CORPORATE
HEALTHCARE
GOVERNMENT
DESIGN
Induction Product 2009
PERFORMANCE SUSTAINABILITY S E R V I C E DESIGN
Induction Product 2009
DAVID OAKEY – WORLD REKNOWN DESIGNER
“One day people like me will go to jail”
Ray Anderson 1994
Interface .,Inc 1973
1994 Interface’s
vision
2020 Our
Mission
HOW THE JOURNEY BEGAN
The Interface Vision
IMAGE HERE
Interface‘s Vision “To be the first company that, by its deeds, shows the entire industrial world what Sustainability is in all its dimensions: people, process, product, place and profits – by 2020 – and in doing so we will become restorative through the power of influence.”
IMAGE HERE
What is Mission Zero?
Mission Zero raises the difficult questions:
Q
Q
Q
Can we eliminate our impact while delivering more to our customers?
Can a corporation do well and do good at the same time?
Can an industry based on petrochemicals really achieve zero impact?
Our roots: the invention of modular floor design
Design Freedom
Glue-free, fast and flexible installation that minimises disruption
Minimal installation waste
The ability to change at low cost
Flexibility to reconfigure and create zones
Easy handling, storage and transport
Convenient uplift to enable reuse or recycling
Easy maintenance Wellbeing
Applying ‘zeroism’ everywhere
For Our Customers
For Our Products
For Our Factories
For Our Value Chain
Zero: Unwanted Noise, Greenwash, Landfill, Carbon, Hassle, VOCs.
Zero: Virgin Yarn, Installation Waste, Virgin Backing, Toxic Chemicals, Secrets.
Zero: Carbon, Fresh Water Usage, Waste, Accidents at Work.
Zero: Petrochemicals, Unfairness, Transport Impacts, Risks.
The Interface Model Seven Fronts of Mt. Sustainability
IMAGE HERE
1. Eliminate waste
2. Eliminate harmful emissions
3. Use renewable energy
4. Closing the loop
5. Resource efficient transportation
6. Sensitizing Stakeholders
7. Redesign Commerce
Towards zero installation waste using Random Design
Normal carpet tile 3 - 4%
Average wastage Broadloom 12%
Random carpet tile 1 - 2%
FRONT 1 : Eliminate Waste
F1
Entropy – inspired by nature Each tile is slightly different in pattern & color
Typical i2 installation waste: 1.5%
Typical broadloom installation waste: 8-12%
Reduced installation waste Reduced manufacturing waste No attic stock, no storage space needed
Sample Return Program • 2005: over 55,000 samples
were returned • 2006: 90,163 samples returned
SIMs • In 2006, 8,000 SIM prints sent • Conserving > 2,000 gal of oil • Keeping 20,000 lbs carpet out of
landfill 1 Carpet sample=1 Qt oil
F1
Zero Carbon emissions Fresh water use Waste Generation Accidents at work
Zero water in our
manufacturing process
F1
Water savings • Exited energy intensive printing
process in 1998
• Water intake per square meter is down 87% since 1996
• Today no wastewater leaves manufacturing area
• No environmental permits are needed ˜ Big cost savings! 1 Carpet sample=1 Qt oil
50 gallons/sq yd
0.9 gallons/sq yd
versus
F1
Ultrasonic machine reduces cutting waste radically
Carpet Die cut Tiles
6 cuts + waste
Carpet Ultra Sonic cut Tiles
1 cut + waste
‘window waste’ with ultra sonic cutting ‘window waste’ with die cutting
F1
Towards zero landfill
F1
Front 2 : Eliminate harmful emissions
F2
COOL CARPET TM
Greenhouse Gas free Carpet
Towards zero carbon with Cool Carpet®
Uses recognised standards
Verified by independent third party
Covers the full life cycle
F2
The Cool Fuel™ program offsets CO2 from company car fuel purchases
Cool Co2mmute offsets GHG emissions from employee commuting
EPA SmartWay Transport Charter Partner, to reduce emissions from ground freight
F2
Towards zero VOCs and better air quality
Emissions requirements from different national legislations and European standards (μg/m after 3 days)
German regulation (AgBB, building products)
French regulation (AFSSET, building productions)
GEV EMICODE EC1 (for adhesives)
Blue Angel RAL UZ 113 (for adhesives)
Gut (for carpet, standard used by Interface)
µg/m3 After 3 days
µg/m3 After 28 days
F2
Zero Carbon emissions Fresh water use Waste Generation Accidents at work
Our factory feeds on bio-gas from fish and chocolate waste
Scherpenzeel down to Zero Front 3 : Use renewable energy
Zero Carbon emissions Fresh water use Waste Generation Accidents at work
Insulating pipes and equipment to avoid thermal loss
Scherpenzeel down to Zero
F4 F3
Zero Carbon emissions Fresh water use Waste Generation Accidents at work
Periodically finding leakages of compressed air
F3
Front 4 : Closing the loop
ReEntry Program
Interface has diverted more than 103 million lbs of carpet since 1994
Transportation
End of Life/ Use
Landfill
Recycling
Use & Maintenance Product Manufacturing Raw material
extraction
Measurement of Global Warming Impact: Where do impacts occur with Carpet? (Closing the Loop)
71%
10% 9% 7%
3%
Greenhouse gas emissions
F4
1
2
3
1. Carpet shipped back to LaGrange, Georgia 2. Full carpet tile is ground up, fiber and backing 3. Agglomerator converts material to pellets
ReEntry Program F4
4
4
5
6
ReEntry Program
4. “Cool Blue Food” sprinkled onto conveyor belt 5. Pellets heated until they ‘ooze’ 6. Backing cured and face fiber added
F4
Transforming our supply chain towards Mission Zero
Front 5 : Resource efficient transportation
Towards zero transport impacts through our local manufacturing
Establish local manufacturing sites
F5
Shifting to lower-carbon modes of transport with railway and barges
F5
Improving transport efficiency
On average our trucks are now 85-90% full
F5
Front 6 : Sensitizing Stakeholders
“Together We Can Reuse It”
F6 GREEN APPLE DAY
F6 Wild Life Conservation
F6 Community projects
F6 Community projects
F6 Mission Zero Week
Front 7 : Redesign Commerce
ENVIRONMENTAL FOOTPRINT COMPARISON OF GRIDSET "GREEN GLUE" vs TACTILES
0
50
100AP
EP
FAETP
GWP
HTP
MAETPODP
POCP
RAD
TETP
EE
Green GlueTactiles
TACTILES Creates a “Floating Floor” Install over existing floors Tiles adhere to one another, not the floor 90% Lower Environmental Footprint Eliminates installation waste
110g
5g
Adhesive per m2
TacTilesTM, per m2
Most emissions from a flooring installation come from the glue
F7
Zero disruption during installation
Renovisions lifts the furniture
and reduces disruption
F7
Zero hassle maintenance
F7
F7
LEED BUILDING
Interface was involved in LEED's development and several of our showrooms and manufacturing facilities have achieved high LEED accreditation. Our Thailand plant is the first LEED Certified building in the country
INTERFACE LEED SITES
Shanghai Showroom – LEED Gold
Atlanta Showroom – LEED Platinum Ray C Anderson Plant, West Point – LEED Certified
InterfaceFLOR Thailand – LEED Certified
F7
Three ways to reduce the biggest impact of a carpet tile:
1 Use less yarn
2 Use recycled yarn
3 Invent a new yarn
F7
Use less yarn
Microtuft: Around 50% less yarn
F7
Today: We have more than 400 colours with 100% recycled nylon
90’s: the inventors of nylon told us it was impossible to recycle nylon
Use recycled yarn F7
Net Works Net-Works is the first step in creating a truly restorative loop in carpet tile production, cleaning up oceans and beaches while also creating financial opportunities for some of the poorest people in the world
F7
Fotosfera is our first product using bio-based nylon yarn
63% bio-based
yarn
Invent a new yarn F7
Towards zero unfairness
F7
Biomimicry – Design inspiration from nature
Nature has 3.8 billion years of design experience
F7
Sustainability Metrics
EcoMetrics - Recycle content - Energy
We measure our progress to Mission Zero along three paths...
PROCESS PRODUCT CULTURE
LCA and Natural Capital - Emissions - Waste
SocioMetrics - Engagement - Safety
Sustainability Metrics: Measuring our Progress toward Mission Zero
“ What Gets Measured, Gets Done “ - Ray Anderson
Product Impacts
70% of Carbon Impacts Occur in the Raw Materials and Production Stage (Cradle-to-Gate)
Average Carbon Impacts by Life Cycle Stage (2013 global weighted average of products sold)
8.56 kg CO2/m2
Product Impacts
Average Cradle-to-Gate Carbon Impacts
8.56 kg CO2/m2
75% of Cradle-to-Gate Carbon Impacts are from Yarn and Backing
(2013 global weighted average of products sold)
2013 EcoMetrics Highlights
ENERGY USE per unit of production since 1996
RENEWABLE ENERGY of total energy use
GHG EMISSIONS per unit of production since 1996
RECYCLED and BIOBASED MATERIALS of total raw materials use
WASTE TO LANDFILL per unit of production since 1996
WATER INTAKE per unit of production since 1996
39%
35%
71%
49%
83%
94%
2013 Renewable Electricity
1. Scherpenzeel Green from Grid + Solar
2. Craigavon Green from Grid
3. LaGrange – Kyle 1&2 RECs + Solar
4. LaGrange– Kyle 3 (ReEntry) RECs
5. West Point RECs Two facilities have on-site solar photovoltaic arrays which produced 17 MWh of electricity and saved 9 tonnes of GHG emissions in 2012 LaGrange - 9 MWh (0.01% of electricity usage) saved 6 tonnes of GHG emissions Scherpenzeel - 8 MWh (0.03% of electricity usage) saved 3 tonnes of GHG emissions
Energy
5 out of 7 manufacturing facilities use 100% renewable electricity:
Happy and Productive Culture
“ Sustainability is in our DNA “ Mission Zero Champions or Ambassadors Engagement – QUEST, Q12, 360. Less is more, C.I., Innovation Safety, Health and Well being. Zero Waste Renewable Accountable