The production departments aggressively practice the PDCA cycle with specific action plans in order to achieve reduction targets. We will also investigate the possibility of utilizing renewable energy at production facilities and achieving zero emissions at all production facilities over the long term.
Environmental responsiveness in Shiseido America, Inc. East Windsor Factory
East Windsor, New Jersey-headquartered Shiseido America, Inc. (hereinafter, "SAI") completed the phase 1 of a fixed-tilt solar power system in May 2007. In August 2010, the company completed the phase 2 of the project by installing a solar tracking system that changes the angle of panels in step with the position of the sun during the day.
With this installation, together with the system that was initially installed, the system is expected to generate approximately 2,300 MWh of power on an annual basis. This will cover more than 70% of electricity consumed annually at SAI using solar power generation. In addition, approximately 1,200 tons of CO2 emissions can be reduced annually by utilizing the solar power generation equipment, ranking the system among the largest installations in the state.
In 2010, SAI received the New Jersey Governor's Environmental Excellence Award.
In addition, Davlyn Industries, Inc. installed the solar power system in April 2012.
|Date operational||May 2007 (phase 1) and August 2010 (phase 2)|
|Annual capacity||Approx. 2,300 MWh|
|CO2 emissions reduction||Approx. 1,200 tons/year|
Furthermore, East Windsor Factory has also been working on recycling Styrofoam, which is used to protect materials when materials are being delivered, since July of 2012. Although we used to dispose it of as landfill waste, we process it internally and sell it as valuable goods. Through this initiative, we can reduce the waste by approximately 7.5 tons per year and approximately 0.8 tons in CO2 emissions.
ZOTOS International, Inc. introduced the wind power electricity generation in Geneva factory
ZOTOS International, Inc. which manufactures products for hair salons, installed the 2 large-scale wind power generators in the Geneva factory (NY, USA) that began operation in December of 2011.
We expect these 2 generators to generate approximately 4 million kWh per year total. According to American Wind Energy Association (AWEA), this is one the biggest power generation facilities (within own premises) among manufacturing companies within the USA.
Operation of these wind power generators can cover approximately 30% of the annual electricity consumption at the Geneva factory.
In 2012, ZOTOS international, Inc. received "2012 Green Power Leadership Award [PDF : 611KB]" from U.S. Environmental Protection Agency (EPA).
|Date operational||December 2011|
|Annual capacity||Approx. 4 million kWh|
|CO2 emissions reduction||Approx. 2,150 tons/year|
Development of Low-Energy Manufacturing Process for Skincare Emulsions
The conventional process of manufacturing emulsions generally has entailed cooling after heating and emulsifying all ingredients. Shiseido has reviewed this process and developed a manufacturing process, whereby a concentrated emulsion is made by heating a small portion of ingredients and then letting the emulsion cool down naturally by diluting it with room temperature water. In addition to reducing energy used for heating, this development has realized a low-energy technique for manufacturing that eliminates the need for a cooling process.
With this change, it is anticipated that CO2 emissions will be reduced by roughly 22 tons annually during production* while also reducing content loss and manufacturing time.
Manufacturing using a low-energy technique is currently utilized for producing ROSARIUM rose body milk RX products and is slated to be consecutively introduced for other products as well.
Introduction of Solar-Powered Lighting and LED Lamps Saves Energy in Kuki Factory
As of May 2010, the Shiseido Kuki Factory has introduced solar-powered lighting in its storage facility, making it the first building of its kind in Saitama Prefecture with a system installed that eliminates use of electricity.
Solar-powered lighting is a new kind of illumination system that uses sunlight collected from rooftops rather than electricity to provide light in buildings.
Reflection plates with specially processed curved surfaces effectively collect sunlight even in the morning or late afternoon, or when the sun is low in the sky in winter. Meanwhile, prism reflection diffuses collected light into the building, brightening up corners of the storage space that had been dimly lit under mercury lights. The solar-powered lighting thereby enhances operational efficiency and safety. Since solar-powered lighting uses solar energy, it also contributes to reducing environmental load by totally eliminating CO2 emissions and does not require maintenance after installation.
Also during this same period, all external lights on the factory premises were changed from mercury lamps to LEDs that consume half as much energy. These two initiatives are expected to help reduce CO2 emissions by about 45 tons annually.
Shiseido Develops a Protective Material for Transporting Products that Offers Flexibility and Recyclability
Shiseido's Osaka Factory and Kakegawa Factory have developed a new environmentally friendly protective material for transporting products. The facilities began using the new material in April 2010.
In the past, the factories' approach to shipping products involved the use of a variety of protective materials according to the shape and quantity of the product, and these materials were typically discarded after shipment due to the difficulty of reuse.
Working with Shiseido distribution partner Hitachi Collabonext Transport System Co., Ltd., the factories developed a standardized system of partitions that can be reconfigured to accommodate a variety of shapes.
These partitions can be folded to segment packaging into two or four compartments, allowing them to be flexibly reconfigured to suit the purpose at hand.
Best of all, they can be folded up into a compact size and shipped back to the factory, allowing their reuse.
Shiseido expects to cut its annual transportation-related CO2 emissions by about 43 tons thanks to a reduction of some 53 tons in annual cardboard use and increases in shipping efficiency made possible by the ability to reuse the partitions.
Environmentally Responsive Vietnam Factory
Shiseido's 15th factory commenced operations from April 2010 as an "environmental model factory in Asia."
At the Vietnam Factory, we have introduced a central energy monitoring system from Japan as an energy saving measure, thereby optimally controlling energy consumption by visualizing energy use within the factory. Additionally, energy saving and ecofriendly measures are also pursued in terms of lighting and cooling and airconditioning equipment through various means such as introducing these systems from Japan and neighboring countries.
Additionally, surplus soil generated from excavation during construction was reused for landscaping the premises rather than disposal, and then achieving zero emissions at the moment.
The Vietnam factory values "sustainability," which is the most important aspect when considering the environment and all the factory workers are continuously engaged in various activities to conserve the environment such as planting trees within the factory site every year. The Vietnam factory will grow as these trees planted by the employees grow.
Process for shampoo using minimal energy
The Kuki Factory has successfully developed a manufacturing process for "SUPER MiLD" shampoo using minimal energy by reviewing the shampoo manufacturing process.
Shampoo is generally manufactured by mixing oil content with a water-based solution to give hair a shiny appearance. In the conventional manufacturing process, manufacturing tanks are heated once in order to evenly mix the oil content in the solution and then cool it down to crystallize the oil content.
In the recently developed new manufacturing method for "SUPER MiLD" shampoo, we can significantly reduce the energy required in the high temperature dissolution/low temperature cooling by using high temperature dissolution for part of the raw ingredients beforehand and reviewing the order and timing to put the rest of the ingredients in the manufacturing tanks according to the formulation.
With this initiative, we were able to reduce approximately 29 tons of CO2 emissions per year and reduce the heating/cooling processes, thus leading to the enhancement of productivity.