About us > CSR Activities > Shilong Plant (China) > Environmental Preservation Efforts and Results

Environmental Preservation Efforts and Results

The Shilong Plant conducts green production based on the ECOSYS concept. We also revise environmental targets every year for the sake of improvement according to the policy set forth by the General Manager.

Actions and Results in FY2017

The priority target for FY2017 was to reduce power consumption and water consumption by 10% of the total basic production units used the previous year and to produce zero emissions (waste recovery ratio = 99.6%). For the results of FY2017, the total production volume improved by 1.0% compared to the previous year. However, since we tried to make efficient use of energy and resources and reduce waste, we successfully improved on the number of basic units used.

Item FY2017 basic unit targets FY2017
results
Converted to absolute volume Judgement
Electric Power Usage 10% reduction (versus the previous year) 0.04% increase 1,336,000 kWh increase Not fulfilled
Water Usage 10% reduction (versus the previous year) 2.9% reduction 7,680m³ reduction Not fulfilled
Zero Emission Waste recovery ratio ≥ 99.6% 99.7% Fulfilled

Efforts to Reduce Power Consumption

We have continuously engaged in efforts to reduce our power consumption over the past nine years. As a result of these efforts, power consumption decreased from 45,110 thousand kWh in FY2008 to 30,150 thousand kWh in FY2017 and the basic unit fell 44.6% in FY2017 from FY2008. Particularly, to conserve energy, we adopted highly efficient motors and introduced energy-saving technologies including energy reuse systems. We continue to monitor the status of our energy consumption in order to more efficiently use energy in line with the Chinese government's policy.

・ Change in power consumption

power consumption

Energy-Saving Efforts in FY2017

  • Development of an energy usage system, with three signboards additionally installed to ensure visualization
  • Installation of timer control units on water heaters in the hot water service rooms (17 units)
  • Shift from ordinary fluorescent lamps to LED lamps (Shift from 40W to 14W, 2,338 lamps)
  • Shift of lighting fixtures in the molding press plant from fluorescent lamps to LED lamps (Shift from 120W to 70W, 63 lamps)
  • Shift to energy-saving compressor drainage pump (1 unit)
  • Application of one inverter to a compressor (1 unit)
  • Reduction in the fan operation time on the production line (from 24 hours to 15 hours) (72 units)
  • Shift from low-efficiency motors to high-efficiency motor (1 motor)
  • Replacement of air-cooled water coolers to an energy-saving type (3 units)

Equipment Remodeling

Freezer unit
High-efficiency motor

Air-conditioning equipment consumes a lot of electricity at our plant. An energy-saving manager is assigned to every air-conditioning system in the plant so that equipment operation is carefully managed. 93 low-efficiency motors were replaced with high-efficiency motors over two years, starting in 2015.
The energy management system was also newly introduced, primarily at sites in the plant where a lot of energy was consumed. This realized "visualization" of energy usage conditions with monitors.
For example, power consumption at night (12 am to 7 am), when there is no production, was monitored, which allowed us to reduce the monthly peak power consumption from 11,480 kWh in 2015 to 4,491 kWh in the same month in 2016. This amounts to a 61% reduction. This system was given the recognition of the A rank by the examination of the Dongguan City authority.

Monitor screen for the energy management system
Monitor screen for the energy management system
System certification
System certification

Target for FY2018

The environmental target for FY2018 is an improvement of 1% or more relative to the previous year for greenhouse gas emission, energy consumption, water consumption, and industrial waste emission. In addition to the elimination of waste, which has been promoted to this point, we plan to promote a remodeling of air-conditioning systems and the use of inverter-type compressors.

Efforts to Reduce Waste Emissions

We have placed personnel in charge of recovering hazardous waste since March 2013 as part of a one-on-one check system for achieving a targeted waste recycling rate of 99.6% or more. For example, oil-immersed waste cloths are checked when they are collected prior to disposal, and if they are disposed of in a wasteful manner, the responsible staff takes its picture and sends it to the department for feedback.
Case examples of wasteful disposal are announced at the monthly Environmental Management Committee meeting that is held to share information among all departments. For example, discarded chemical containers are often found to still contain a lot of material such as grease. The major cause of this is that the opening of the container is so small that it is impossible to completely use up the content inside the container. To solve this problem, we developed a dedicated tool to reduce the residual chemical content, and also take actions to reduce the generation of such waste. We intend to completely check the properties of wastes, identify the source causes that create waste, and promote measures to reduce waste.

・ Change in waste emissions

Change in waste emissions

Reuse of Waste

We established a waste reuse system designed to promote the reuse of resources in December 2008, in order to reduce waste emissions and make effective use of resources. In this system, when a department applies for permission to dispose of certain articles, the articles are checked, those that seem to be valuable enough for reuse are collected, and photos and specifications of the collected articles are entered in a database. The system then calls upon other departments to reuse those articles. In FY2017, there were 4,031 cases where effective use was made of used articles that would have otherwise been disposed of.

• Case Example of Resource Reuse

Plastic bags for toner packaging
Plastic bags for toner packaging
Resin gloves
Resin gloves
Rubber bands for toner packaging
Rubber bands for toner packaging

Promotion of Green Purchasing

Our plant actively promotes green purchasing in order to reduce waste emissions at source. As a main example, in the past, cardboard container boxes were used for parts delivery. Today, we have replaced them with sturdy plastic returnable containers.

Reduction in Water Consumption

The water consumption basic unit target for FY2017 was a 10% reduction. Though reducing water consumption is recommended as a constant effort, water treated from an industrial wastewater treatment facility is reused to water green areas and clean walkways. Through these efforts, reduction in both water consumption and wastewater emission is being promoted at our plant.

Wastewater Treatment Measures

Wastewater treatment facility
Wastewater treatment facility

Our plant has one industrial wastewater treatment facility and two domestic wastewater treatment facilities. The quality of treated water is measured every week. An external contractor is also employed to regularly measure treated water. We always comply with the wastewater regulations of Dongguan and have passed all unannounced inspections of the municipal government.

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