Global Technology Center Scheinfeld
Environmental Statement 2010
Contents
Foreword 1 Company Portrait of the adidas Group............................................................................................... 6 2 Group Environmental Strategy ........................................................................................................ 10 3 Scheinfeld Site................................................................................................................................... 12 4 Data and Facts at the Site ................................................................................................................ 19 5 Environmental Programme – Objectives and Measures................................................................ 24 5 Objectives achieved 2006 - 2009....................................................................................................... 25 6 Validation........................................................................................................................................... 26 7 Contact Partner on Environmental Issues....................................................................................... 27
Foreword At the forefront of sustainable environmental management As a global leader in the sporting goods industry and a responsible company, we declare our commitment to the implementation of sustainable business practices in our own company, as well as in our supply chain. We strive for all areas of our business – including our suppliers – to have consistent values and to implement them. Our aim is clear: to raise the performance of our own sites and of those in our supply chain in the areas of social and environmental responsibility, and in this way to improve the lives of the people who manufacture our products, as well as the environment in which they are manufactured. In the context of growing environmental challenges, progressive environmental management systems are an integral part of operational processes today. They form an important basis for the systematic and continued improvement of environmental performance. The Scheinfeld site is at the forefront of introducing ground-breaking environmental management systems, both as a part of the adidas Group and within the global sporting goods industry. The environmental management and environmental statement of the site were successfully validated first time according to the EMAS directive in 1998. The 2010 Environmental Statement of the adidas Global Technology Center in Scheinfeld, Germany, continues to pave the way in environmental responsibility and sustainability. It contains information regarding the centre’s environmental performance over the past three years and describes concrete programmes aimed at continued improvement of environmental performance, as well as quantitative information regarding the environmental impact of the site.
Example for international partners
Creating sustainability in a concrete way
For companies who wish to embrace today’s growing expectations in terms of social responsibility,
At the adidas Scheinfeld site, we are aware of the value placed on the issues of health, workplace and
environmental protection, health and safety and business success, the introduction of a management
environmental protection. Conserving natural resources, avoiding accidents everywhere and at all times,
system is increasingly important. adidas Scheinfeld, the only footwear factory still owned by the
acting in an environmentally-aware way, over and above what is legally required – the adidas Group’s
Group, was successfully revalidated according to EMAS III in July 2010, along with the test centre, the
approach to sustainability has a concrete application at Scheinfeld, achieving durable integration of
training centre and the export/distribution department on the same site. This confirmed our ongoing
environmental issues, people’s expectations and the interests of the company. The Environmental
commitment to the environment, as well as certifying our efforts to-date.
Statement represents an encouraging starting point for future activities that we see as necessary and which we will take it upon ourselves to implement.
With the successful implementation of environmental and quality management systems at the Global Technology Center Scheinfeld going back to the mid-1990s, it was recognised early on that not only could the company’s environmental impact be consistently reduced but that operational costs and therefore the competitiveness of the site could also be optimised as a result. We therefore encourage our international business partners, who manufacture the majority of our products, to develop similar systems and to gain certification according to international standards for environmental protection, health and workplace safety. Part of our global social and environmental programme includes supporting our suppliers with case studies and valuable experience to help them manage and organise their premises in an environmentally-friendly manner. The experiences we share in the context of environmental management systems actively help our business partners in their journey to develop sustainable business practices. Many of them have followed the example of Scheinfeld and successfully established comparable systems.
Ulrich Bauer Head of Footwear Sourcing Europe
Josef Mayr Head of Global Technology Center Scheinfeld
Frank Henke Global Director Social & Environmental Affairs
1 Company Portrait of the adidas Group 1.1 What we do
The adidas brand is also headquartered in
endeavour to maintain the correct balance
For over 80 years, the adidas Group has been
Herzogenaurach. Reebok is based in Canton,
between the interests of our shareholders, on
part of the world of sport, delivering state-of-
Massachusetts and TaylorMade-adidas Golf is
the one hand, and the needs and considerations
the-art sports footwear, apparel and accessories.
located in Carlsbad, California. The company
of our employees and those working along our
Today, the adidas Group is a global leader in the
also operates Creation Centres and development
supply chain, and environmental issues, on
sporting goods industry, offering a broad portfolio
departments at other locations around the world,
the other. In brief, we strive to be a sustainable
of products that is available in almost every
corresponding to the related business activity.
company. To this end, we have developed a
country in the world. Our strategy is simple: to
adidas Sourcing Ltd., a fully-owned subsidiary
number of strategies in order to:
strengthen and develop our brands and products
headquartered in Hong Kong, is responsible for
• Encourage innovative thinking in product
in order to improve our competitive position and
worldwide sourcing. As of December 31, 2009, the
our financial performance.
adidas Group employed 39,596 people.
The activities of the company and its more than
The adidas Group is a global company in the
170 subsidiaries are directed from the Group’s
sporting goods industry. As such, we are
headquarters in Herzogenaurach, Germany.
constantly faced with new challenges and we
development and product design.
• Support our suppliers, should employment, health or safety problems arise in their factories.
• Improve the environmental impact of our sites and throughout our supply chain.
• Encourage employee retention and development and the building of a safe, The adidas Group supplies products under the following brand names:
adidas
Footwear, apparel and accessories
Reebok
Footwear, apparel and accessories
TaylorMade- Golf Equipment: metal woods, irons putters, adidas Golf golf balls, footwear, apparel and accessories
inspiring and performance-orientated workplace.
• Maintain an open dialogue with local communities and stakeholders, whose feedback gives us the impetus every day to improve.
6 /// Environmental Statement 2010
1.2 Our Sustainability Statement
PERFORMANCE • PASSION • INTEGRITY • DIVERSITY
These are the adidas Group values.
It is about setting workplace standards for our suppliers to meet and helping them to ensure fair, safe
They help us to create brands that our customers
and healthy conditions in their factories.
believe in and they commit us to playing by the rules
Importantly, it also means looking after the wellbeing
that society expects from a responsible company.
and careers of our employees - the company’s biggest
Unlike in sport, society’s rules are not always written
asset - and making a positive contribution to the
down. We discover them by engaging with the people
communities where we operate.
that our business touches, learning above all, that companies are expected to be accountable for their
Adhering to all applicable laws, directives and
actions. So we are committed to reporting publicly on
guidelines is a business imperative. But that is not
the steps we take to have a more positive impact on
enough. We are continuously striving to improve our
society and the planet.
performance and our standing in society. We set ourselves targets that stretch us, regularly review our
For the adidas Group, this means designing products
progress and set ourselves new goals. That is what the
that are environmentally sound, and reducing the
world’s leading athletes do, and it is what we must do
environmental impacts of our day-to-day operations
as a global leader in the sporting goods industry.
and in our supply chain.
Environmental Statement 2010 /// 7
1.3 Global Technology Center –
The Scheinfeld site shares its core objective with
Function within the Group
that of the company and its founder, Adi Dassler
About 40 kilometres from Herzogenaurach and the Headquarters of the adidas Group, lies the only production facility for footwear owned by the company. The site, which today employs about
1959 Construction of the footwear factory in Scheinfeld. 1961 Start of lightweight trainers and football boots production; intensive involvement in the development of innovative sports footwear concepts.
– namely to supply athletes with footwear that has been specially developed for their sport, and specially produced just for them.
130 people, was established in 1959.
1962 Inauguration of the first facility to directly inject soles made from thermoplastic polyurethane and rubber onto sports shoe uppers. 1974 Inauguration of the first polyurethane plasticized foam injection machine for the manufacture of single-colour sports shoe soles.
boot models “Copa Mundial” and “World Cup”,
The successful development of the adidas
1980 Large-scale standard production of sports shoes with directly injected and cemented soles.
makes made-to-measure (m2m) and designer
1987 Step-by-step development of the footwear factory to a facility of high innovation and technology.
disciplines. The site also contains training and
Group through the adidas brand into a global leader in the sportswear industry is closely tied to the achievements of the Scheinfeld site. Since its establishment, this footwear factory has continually participated in the development and implementation of product and process innovations, and with their excellent skills and qualifications, the employees there actively support the construction and technical development of the production facilities of its international business partners.
1997/1998 The manufacturing facility in Scheinfeld receives the title ”Global Technology Center”. The international training centre for sports footwear technicians, the materials laboratory for the testing of sports footwear and ball material and the test centre for innovative product developments are integrated. 1998 Introduction of an integrated quality and environmental management system. First-time validation according to EMAS and ISO 9002 certification. 1999 Launch of the international training centre. 2000 Launch of the professional training programme for shoemakers – the Engineering Qualification in Shoe Technology in association with the Pirmasens FH (technical institute). The facility receives the Safety at Work Award 2000. 2001 Recertification according to ISO 9001:2000, EMAS II revalidation. 2002 Installation of a new assembly line using new production technology for shoe manufacturing. 2003 Continuing automation in footwear production and use of new cementing processes leading to significant reduction in the use of adhesive materials. 2004 Recertification according to ISO 9001:2000, EMAS II revalidation. 2005 Extension of football boot production; integration/relocation of the finishing division from Uffenheim to Scheinfeld.
8 /// Environmental Statement 2010
2007
Recertification according to ISO 9001:2000, EMAS II revalidation.
2008
”Connectivity” Award given to the m2m department by adidas AG for excellent customer service.
2009
50th anniversary of the Scheinfeld site.
”Sustainable Environmental Practices” Award from adidas AG for its years of success in implementing sustainability ideas.
As well as standard production of the footballthe Global Technology Center in Scheinfeld also footwear, as well as special footwear for Olympic education centres and hosts information events. Scheinfeld trains prospective shoemakers and accommodates the test centre for research and development, as well as finishing and distribution facilities.
The Global Technology Center in Scheinfeld is an organisational component of the adidas Group. Besides this manufacturing facility, the Group works with other independent contractors, whose production sites are located throughout the world. Within the global corporate organisational structure of the adidas Group, the Global Technology Center and its production are part of global footwear sourcing operations. About 19,000 m2 of the approximately 56,000 m2 site has been built upon. Spread across various levels in the buildings are around 24,400 m2 of warehousing space, 3,300 m2 of administration and office space and 4,000 m2 of production space.
Environmental Statement 2010 /// 9
2 Group Environmental Strategy
As a global company with offices in more than 55
2.1 Elements of the environmental strategy
Product development
and track their environmental performance and
countries, the adidas Group has a responsibility
along the value chain
Our developers work closely with our
that their progress is of extreme importance to
to protect the environment and conserve it for
Marketing
manufacturers in order to ensure that products
our business relationship.
future generations. Environmental impacts occur
Marketing is about creating innovative concepts
are made according to our standards. To
at all stages of the lifecycle of our products,
and determining how to make our products
achieve this, they generate detailed technical
Own operations
from product design to disposal. The aim
successful in the marketplace. Within product
specifications, taking into consideration issues
We employ almost 40,000 people in more than
of our environmental strategy is to manage
development, we have the opportunity to
such as the environmental impact of various
170 subsidiaries throughout the world. Our own
environmental effects throughout the value chain.
demonstrate our environmental credentials.
materials. We measure the environmental impact
premises comprise offices and a small number
We have introduced special ranges of more
of the materials we use, including the resources
of production facilities and warehouses. At these
The focus will always be on the following:
sustainable products, which are made with
necessary to produce the raw materials. Our
facilities, energy, water and other resources, such
• Sustainable use of resources • Avoidance of and reduction in emissions • Limiting risks and chemical hazards.
recycled materials and with the lowest possible
aim is to only choose those materials which
as paper, are used and waste is produced.
environmental impact.
demonstrate the most limited use of resources.
Design
In addition, we encourage the use of recycled
Therefore, we have set environmental targets
materials.
for our own sites. For example, to reduce our relative energy use by 20% by 2015. To achieve
Our designers endeavour to create products that
10 /// Environmental Statement 2010
meet the needs of our customers – both in terms
Sourcing and manufacture
this, we have created “Green Teams” made up
of performance and design. The decisions taken
Most of the environmental impact occurs during
of employees tasked with encouraging their
by our designers can have significant impact on
the production phase. We should emphasise
colleagues to make a contribution towards
the environmental impact of our products in later
that almost all production is carried out by
protecting the environment.
stages of the process. For example, the easier
independent suppliers, not by us. However,
and more standardised we make our patterns,
we support our manufacturers in reducing the
the less waste and emissions will result at time of
environmental impact of the various production
production.
processes. Our suppliers know that we measure
Transport
In detail, this means on a Group-wide basis:
The fuel used to transport products from their countries of manufacture to their respective markets creates carbon dioxide emissions, a major contributor to climate change. In order to minimise the environmental
Topic
Target
Deadline
Energy and Carbon (1 Water (1
Reduction of relative energy use by 20% +10% relative carbon savings through greener energy sources In total: 30% carbon savings
2015
20% water savings per employee
2015
Resources – Paper (1
50% paper savings per employee
2015
Waste (1
Reduction of household waste by 25% per employee
2015
Mobility (1
Business Trip Management: Reduce emissions caused by business travel to 570 kg CO2 per employee “Green” Company Car Policy: Reduce carbon emissions caused by the company car fleet by 30%
2015
Purchasing and Canteens
No use of one-way dishes or non-compostable one-way dishes Develop a Group-wide green purchasing programme
as of 2010
Green Buildings Employees
All new buildings projects to be assessed for their environmental impact and potential
as of 2010
Green Teams – locations with more than 50 employees to establish Green Teams adidas Group Green Day together with “Earth Day” at 20 locations worldwide
as of 2010
impact of transportation as much as possible, our products are shipped by sea for the most part. Use and disposal When products reach the end of their useful life and must be disposed of, they contribute to society’s growing waste problem. The disposal of used products depends on local conditions and regulations. We are reducing waste by building in more recyclable parts into our shoes. 2.2 Group-wide environmental targets An organisation does not become sustainable overnight. When it comes to our own operations, we have put into place Group-wide targets up to 2015 within the framework of the Green Company initiative, which began in 2008, in order to consistently reduce the environmental impact across the entire Group. A key one is the relative reduction of energy use by 20%. On top of that, we want to reduce CO2 emissions by a further 10% by using renewable energy. These objectives are in line with our overall carbon strategy that prioritises: 1. Lower energy consumption and intensity. 2. Energy sources with lower carbon emissions. 3. Consideration of carbon offsetting mechanisms.
(1 Baseline 2008
Further information on the global social and environmental programme of the adidas Group and the social and environmental reports that are regularly published can be found on our website: www.adidas-group.com/sustainability
Environmental Statement 2010 /// 11
3 Scheinfeld Site 3.1 The Scheinfeld site and its areas of
Finishing
The Test Center
operation
In November 2005, finishing was relocated to
Established in 1997 as the company‘s own testing
Footwear production
the Scheinfeld site. The core task of this area
institute, the Test Center comprises three areas:
With currently 65 employees working partly in a
is to finish nearly all available articles in the
multiple shift system, the Scheinfeld site mainly
current adidas collection that have motifs, e.g.
produces the ”Copa Mundial” and ”World Cup”
sponsorship or team logos, player names and
• Materials laboratory • Ball and accessories laboratory • Biomechanics laboratory
models, making several thousands of pairs each
numbers, and event logos. These include textiles,
day. The most important steps in the process
sports equipment and accessories. Mainly
The primary responsibility of the materials
are the preparation, assembly and finish; and
team sport articles, such as football jerseys,
laboratory is quality assurance in sports footwear,
specialised machines and automated production
tracksuits, sports bags etc. are equipped with
balls and accessories. The materials laboratory in
steps are used as much as possible.
related symbols. The finishing processes used
Scheinfeld uses both physical as well as chemical
are transfer, direct print, pad print, embroideries
methods to test materials. Testing is carried out
Another part of production is the ”made-to-
and individual or special solutions. Customers
in accordance with our own specifications and
measure” (m2m) area with customisation and the
are solely internal departments in the adidas
the German DIN standards, in addition to other
manufacture of individual pairs of shoes. These
Group that deal with sports people, associations
international standards such as the American
include shoes for people with foot or orthopaedic
and teams. About 22 employees work annually
ASTM standard.
problems, as well as for adidas athletes who need
on approximately 800,000 articles, which are
tailored and individualised shoes for their sport.
then dispatched. The finishing process is fully
Furthermore, the materials laboratory performs
integrated into the environmental management
analyses on product materials that are to be used
EMAS of the site and all processes and materials
as alternatives to PVC. General avoidance of PVC
used correspond to the adidas ”Best Practice
materials in products is an important aspect of
Standard”, i.e. PVC-free materials, least possible
the company’s materials strategy.
use of solvents and a modern and friendly working environment.
12 /// Environmental Statement 2010
The ball and accessories laboratory is essentially
Distribution/Export
Legislation
Support
responsible for developing and researching
The shipping/export department in Scheinfeld I,
We adhere to social and environmental laws,
We support social and environmental projects
materials for all types of balls, as well as
which has warehousing of approximately
directives and guidelines while continually
and develop partnerships with businesses and
protective and performance equipment, such
15,000 m2, is responsible for the worldwide
improving upon our own contribution to a
organisations whose direct and indirect output
as shin guards and goalkeepers’ gloves. The
distribution of sports goods. Equipment for large
sustainable society.
contributes to a sustainable society.
biomechanics laboratory, known as the Biolab for
sporting events such as the Olympic Games, the
short, is part of the adidas innovation team (a.i.t.):
World and European Championships are sent to
Management
Stakeholder dialogue*
the department that works on medium- and long-
the host federations.
We aim to:
We aim to listen, respond and interact with
• analyse, evaluate and assess the social and
all stakeholders in an atmosphere of mutual
term product and technological innovations in footwear, apparel and hardware.
While considering contractual and legal
environmental impact of new products,
trust and respect. We provide them with
stipulations, the appropriate means of
technologies and processes at the design and
appropriate information related to the social and
development stage,
environmental performance of the Group on a
Training Center
transport and routes are determined so that the
The Global Training Center is an educational,
quality of our products is not affected during
conference and exhibition centre, approximately
transport. Transport is carried out in a way as
2000m2 in area, offering rooms, facilities
environmentally-friendly as possible.
• publish the results.
conferences of all kinds. As well as conferences,
3.2 Environmental policy of the site
Supplier and customer relationships
seminars and training rooms for employees of the
The principles, as set out in the adidas Group’s
We expect suppliers’ activities to be compatible
adidas Group, there are also guest offices, and
Sustainability Statement, apply to all operations
with our ”Workplace Standards”, the code of
exhibition rooms related to shoe production and
worldwide and are the benchmark for assessing
conduct for the supply chain of the adidas Group.
the company’s history.
our own progress in the areas of social and
We work in partnership with them to improve
environmental responsibility. They form the basis
our collective performance. We encourage our
for the environmental policy at the Scheinfeld site.
business customers to take a proactive stance on
• set up clear targets, formulate an action plan
regular basis.
and monitor progress,
and equipment for training, education and
* Interest groups, e.g. employees, community members, suppliers, organisations, customers, banks, insurance companies, shareholders
the social and environmental impact of their own activities. Environmental Statement 2010 /// 13
adidas Group Social & Environmental Affairs
Site Management GTC Environmental Representative (on Senior Management Level)
adidas Group Facilities & Services
Coordination Quality/Environment
3.3 Environmental Management System
The Scheinfeld site does not operate equipment
With the support of the Group function ”Social
that requires authorisation, but the continually
and Environmental Affairs” and the ”Facilities and
changing (and ever increasing) statutory
Services” organisation, industrial environmental
requirements are ensured by means of a well-
protection at the site is implemented by the senior
structured environmental management system.
management representative, the coordination
Environmental objectives and programmes are
function ”Quality and Environment”, and the
established by the site manager in cooperation
environmental representatives from all relevant
with the Environmental Delegate and the
sectors.
members of the Eco Audit Team, and their implementation is tracked on an ongoing basis.
Footwear Production Waste Management Emissions Energy Management Hazardous Materials Water Management Risk Management Fire Protection
An efficient, integrated environmental and quality
The manner in which the environmental
management system facilitates the systematic
management system is organised has clearly
development of industrial environmental
proven itself in the 12 years of its existence.
protection, since the operational activities at the
Regular training sessions and open discussions
Finishing
Scheinfeld site naturally also have an impact
have had the effect of anchoring environmental
Distribution/Export
on the environment. Measures are organised,
awareness at all levels of the workforce.
coordinated and monitored based on the
Regular in-house environmental operational
environmental management system to ensure
checks firstly ensure that the effectiveness of the
that they reduce the direct environmental impact.
management system is permanently monitored
Warehousing Test Center
Environmental Delegate
Training Center Facility Engineering Canteen
and, secondly, document the functionality Production and other activities at the Scheinfeld
of the environmental programmes defined.
site have been continually adapted to the
Adherence to statutory requirements is checked
demands of contemporary environmental
regularly and validated through the ongoing
protection since 1998.
support provided by the external INTECHNICA consultants.
14 /// Environmental Statement 2010
Cutting Cutting Punching
➜
➜
Sewing
➜
Energy use Noise emissions Dust emissions Waste
➜ ➜
Energy use Solvent emissions Waste
Screen/Pad printing Printing Drying
➜
➜
Energy use Noise emissions Dust emissions Solvent emissions Waste
Heat transfer printing
➜
Assembly Roughing, Cementing, Cleaning, Painting, Drying
Electricity consumption Compressed air consumption Non-hazardous waste
Pre-printing Screen coating Screen exposure Screen cleaning Screen coating removal
Transfer film CAD artwork Printing Packing
➜
Electricity consumption
➜
Bottom preparations Roughing Cementing Cleaning Painting Drying
Energy use Noise emissions Dust emissions Solvent emissions Waste
➜
Stiching preparations Stamping Sharpening Roughing, Cementing Painting, Punching
< 3.4 Footwear production and its environmental impact
3.5 Finishing and its environmental impact
➜
➜
Energy use Noise emissions Dust emissions Solvent emissions Waste Waste water
➜
Energy use Noise emissions Manufacturing waste Materials (leather, fabrics)
➜
Bottom components Rubber TPU EVA processing
➜
➜
Energy use Noise emissions Dust emissions Solvent emissions Waste Waste water
Finishing Cementing, Colouring, Spraying, Cleaning, Wrapping
➜
➜
Electricity consumption Water consumption Cleanser Solvent emissions Colour leftover Waste water
Electricity consumption Gas consumption Compressed air consumption Waste heat Solvent emissions Colour leftover
Shipping Packaging
Environmental Statement 2010 /// 15
3.6 Environmentally-aware behaviour
to match the ergonomic requirements of each
Input materials
at the site
employee and the revised processes.
By working in close cooperation with adhesives
Improving protective environmental practices
16 /// Environmental Statement 2010
suppliers and machine manufacturers, we
in our operations is an ongoing effort and we
Material and energy efficiency
are continually striving to replace adhesives
consider it important to include our employees in
Material-efficient systems engineering
containing solvents. While no satisfactory
this process and to keep them informed.
An ongoing development of products, materials
solutions have yet been found for some steps of
and technology means that processes are
the process, for others, for example cementing
Safety at work
continually improved. We have analysed and
insoles, the most up-to-date heat adhesive
The right of employees to work in a safe and
compared specific equipment related to energy
processes have been successfully introduced. We
healthy environment is our overriding priority.
and material use and output ratios from an
are currently exploring new technologies, such
A high standard of health and safety in the
early stage. By introducing equipment for direct
as dispersion adhesives which, when launched
workplace has continued in our footwear
soling of the â&#x20AC;?Copa Mundialâ&#x20AC;? football boot, and by
in mass production, should significantly reduce
production since our modern work safety
making some necessary adjustments to improve
solvent emissions.
management system was awarded first prize by
quality, the raw material used in the sole could be
the Textil- und Bekleidungsberufsgenossenschaft
reduced by 10%. At the same time, unavoidable
Where solvents have to be used, we always try
(Textile and Clothing Trade Association) in 2000.
production waste has significantly decreased.
to find less volatile substances. This reduces the
In 2009, for example, there were no occupational
For example, by making changes to the individual
impact on the environment and contributes to
accidents reported by production personnel.
shoe components and processing steps we were
better workplace conditions for our employees.
Since the year 2000, further precautionary
able to significantly increase the efficiency of our
measures have been developed and implemented
soling machinery. Significant improvements are
by means of regularly checking for potential
not always possible; however, taking into account
dangers to health and safety in production-related
the sum of small and large changes in the area
working areas. For example, all cementing and
of equipment technology, production is getting
finishing workplaces were adjusted and optimised
increasingly material- and energy-efficient.
Noise emissions
Individual traffic
Energy meters and peak load management
When installing new equipment and machines,
As in previous years, workers at Scheinfeld are
Power supply in the site is monitored with a
we always take into account possible noise
provided with several minibuses to help them on
Peak Load Management System so that peaks in
pollution. For workers employed in areas where
their daily commute to work and to limit as much
consumption can be minimised. When replacing
noise cannot be avoided, we provide individually
as possible the danger of accidents. In 2009, the
energy distribution equipment, energy meters
adjustable and controllable ear protection, called
provision of this service accounted for 165,000
were installed. By installing more sub-meters,
variphone otoplastic. The otoplastic is adjustable
shuttle kilometres. This facilitated the saving
a better distribution of energy consumption and
depending on noise levels.
of many times this amount in private journey
better specific consumption output is possible.
kilometres, as well as reducing the emissions and
Currently the production facility can be measured
environmental damage they would have caused.
separately from warehouses, kitchen areas, the
Waste management Unavoidable waste is separated and recycled.
Test Center and offices.
Apart from special materials (for example, waste from exhibitions is also disposed of through our site), we try to maintain our current level and, wherever possible, instigate improvements in waste management.
Environmental Statement 2010 /// 17
Energy purchase
The purchase of heating oil is subject to price
Protocol, cut down on CO2 or methane (CH4)
up to a year. During this purification process, a
Since the liberalisation of the energy market,
developments in the market. The requirements
emissions generated by energy production
large amount of the greenhouse gas methane
energy purchase has been centralised and is by
of several sites are bundled together as far as is
elsewhere. As greenhouse gases have a global
is produced. By constructing a new waste water
national tender. By bundling together several
possible to achieve better prices and to ensure
effect on climate change, it is not relevant where
treatment technique and a biogas reactor, the
production, warehousing and administration sites,
that delivery vehicle journeys are optimised.
the reduction in emissions occurs in the world.
methane, which is harmful to the climate, no
three-year contract periods, it is possible to plan
CO2-neutral natural gas supply
The CDM projects include a geothermic
collected and used as biogas in block heating
safely in the medium-term, and we have currently
In order to bring the vision of a â&#x20AC;&#x153;zero-emission
generating plant in Indonesia. The power plant
stations for the production of electricity and heat.
negotiated contracts up to 2011. When signing
companyâ&#x20AC;? in the context of the Green Company
is located in Gunang Salak, 70km south of the
The annual saving in CO2 is a massive 96,000
contracts, we look at cost transparency, detailed
initiative a step closer, the adidas Group has
Indonesian capital of Jakarta. The plant uses
tonnes!
invoicing, access to web-based consumption
moved to a CO2-neutral product for its natural gas
geothermal energy as an energy source and
data and prices that are unaffected by volume
supply at its sites in Herzogenaurach, Scheinfeld
supplies electricity that is generated using three
variations. Within the framework of company
and Uffenheim. In this way, we are making an
steam turbines. Around 115,000 tonnes of CO2 are
targets for the reduction of CO2 emissions, the
active contribution against advancing global
saved here per year.
criterion of indirect CO2 emissions through
warming.
longer enters the atmosphere, but is instead
competitive prices can be negotiated. With two- or
Another project being funded is a combined
electricity supply is constantly monitored. At the moment this is showing an excellent specific
With a small extra charge on the negotiated gas
biogas and waste water treatment plant 20km
value of 253g CO2/kWh.
price, worldwide climate protection projects,
east of Nakhorn Ratchasima, one of the largest
called CDM (Clean Development Mechanism), are
cities in Thailand. The waste water from the
being financed by the provider. These projects,
production of starch from the cassava plant has
which are monitored according to international
been gathered in large tanks for many years and
standards and the quality standards of the Kyoto
has been biologically purified over a period of
18 /// Environmental Statement 2010
4 Data and Facts at the Site The economic development of 2009 also had an impact on the Scheinfeld site and there was a dramatic slowdown in footwear production. As a result, many of the figures shown here were affected.
Materials used in footwear production
2006
2007
2008
2009
Raw materials, shoe production
Drinking water consumption Sanitation purposes (m3)
2006
2007
2008
2009
1,647
1,420
1,677
1,353
Leather and textile materials (m2)
227,500
335,314
313,519
221,030
Sprinkler checks (m3)
21
10
32
47
Granulated PU (t)
97.2
143.6
134.9
95.1
Total consumption (m3)
1,668
1,430
1,709
1,400
Leather dyes (kg)
87.4
129.0
120.0
84.6
Energy consumption
2006
2007
2008
2009
Semi-finished products (t)
133.9
170.0
159.0
112.1
Electricity (kWh)
1,557,000
1,657,000
1,639,000
1,453,000
Small items (t)
14.2
21.0
19.6
13.8
Natural gas (kWh)
4,144,000
3,941,000
4,175,871
3,320,000
Shoe boxes and outcartons (t)
136.2
201.0
188.0
132.5
EL fuel oil (kWh)
324,000
325,000
222,000
279,000
Labels and adhesive tapes (t)
1.74
2.55
2.39
1.62
Total consumption
6,025,000
5,923,000
6,036,871
5,052,000
Waste
2006
2007
2008
2009
Adhesives, thinners and solvents (t)
11.6
12.09
11.25
7.39
for recycling
Shoes produced (pairs)
593,706
791,584
739,860
518,254
Paper and cardboard packaging (t)
156.0
133.3
160.8
142.0
Films (t)
6.6
6.7
6.2
6.0
Material components for finishing
2006
2007
2008
2009
Wood (t)
16.10
18.90
35.80
15.98
Green waste
-
-
-
-
Plotter flock (m2)
1,450
1,400
1,300
778
Flourescent lamps*
-
-
-
-
Plotter foil (m2)
3,500
2,449
2,000
1,978
Used solvents, adhesive residue* (t)
-
0.3
-
-
Colours (screen and pad printing) (kg)
200.0
325.0
250.0
225.0
Waste for thermal recovery (t)
47.6
44.0
61.3
58.94
Screens (pcs.)
316
408
370
160
Industrial waste (t)
4.53
4.80
4.50
1.59
Printing plates (pcs.)
130
225
275
450
Biowaste, food leftovers (t)
1.20
1.26
1.20
1.34
Pieces finished
794,500
812,539
885,000
811,178
Grease separator contents (t)
2.00
2.00
1.90
1.86
Used solvents, adhesive residue* (t)
-
0.02
0.91
0.56
Obsolent varnishes and paints* (t)
-
0.37
0.09
-
Supplies containing solvents, solid*
-
-
-
-
Ancillary materials and supplies
Raw materials for finishing
Additives
for disposal
* Waste requiring special monitoring
Environmental Statement 2010 /// 19
4.1 Key Performance Indicators (KPI)
4.2 Water/waste water
According to Annex IV of regulation (EC) number
Already low, water consumption fell by 18%
1221/2009 (EMAS III), the environmental
compared to the previous year, to 1,400 m3.
statement should include certain defined key
Since no water is used in the production process,
indicators, which deal with the same reference
this relates solely to consumption for sanitation
figure (gross value in Euros or total output volume
purposes and sprinkler checks.
in tonnes). Due to the great variation of the activities and processes which take place at the
Going back to previous years, we also have the
site, this manner of measuring our environmental
following key data on water consumption per
performance is not possible. In terms of
employee and day.
regulation, the key indicators for the base year 2009 are nevertheless indicated as follows.
The values between 35 and 47 l/employee*day
As a base value, the gross weight â&#x20AC;&#x201C; including
in past years approximately correspond to water
packaging materials â&#x20AC;&#x201C; of the football boots and
use for the toilets and are at an acceptable and
sports shoes produced has been used.
expected level.
As in the environmental statements of the past 12 years, we will continue to track the most important specific key figures and, where it is practical and possible, we will present and discuss other key data.
KPIs Unit Value
Output ref. values [t]
KPI
Energie efficiency
[kWh]
5,457,387
428.9
12,724
Share of reusable electricity (27,9%)
[kWh]
405,387
428.9
945.2
Material efficiency of packaging
[t]
134.12
428.9
0.31
Water
[m3]
1,400
428.9
3.26
Waste
[t]
228.2
428.9
0.53
CO2-emissions
[t]
736.5
428.9
1.72
VOC-emissions
[kg]
4.459
428.9
0.0104
Area [m2]
20 /// Environmental Statement 2010
19,000 56,000 (under roof) (Total)
33.9
4.3 Energy
Water consumption per employee and day (l)
Specific electricity consumption shoe production (kWh/pair)
Total energy consumption fell by approximately 16% in the period 0
10
20
30
40
2006-2009. The use of gas for heating purposes and the small
50
0.0
amount of heating oil used fell by about 19.5%, while electricity
2006
consumption fell by 6.8% in comparison. The changing use of
2006
2007
halls in previous years make comparisons difficult, so we have
2007
2008
been trying to get energy consumption data separated by halls in
2008
2009
order to have a better basis of information for evaluating specific
2009
0.2
0.4
0.6
0.8
1.0
consumption. Separate recording of gas consumption for the drying ovens used in the finishing process has also taken place. Sanitary facilities
Sprinkler checks
With approximately 1,040 m2, the drying process accounts for only
in m3 Werte in m2
0
500
1,000
1,500
a fraction of total gas consumption.
Electricity
With hall and use-specific evaluation of electricity consumption,
2,000
0
we can achieve a better estimate of specific consumption. Average
1995
1996
energy consumption to make a pair of football boots was
1996
1997
0.81 kWh in 2009. In comparison with the previous year, there was
1997
1995
1998 1999
2.500
3.000
an increase in this key figure due to tighter capacity utilisation
2001
utilisation, an improvement is expected here and the 2007/2008
2001
2002
value of approximately 0.7 kWh per pair of shoes will be achieved
2002
again. Aims to make further energy savings in heating and
2003
2005
electricity consumption are being rigorously pursued.
2006
3,000
4,000
5,000
6,000
2000
2004 2005 2006
2007
In spite of this, technical developments and increasing demands
2007
2008
in terms of quality assurance mean that additional equipment
2008
2009
2,000
in 1.000
1999
and fluctuations in capacity utilisation. With increasing capacity
2004
1,000
Natural gas
1998
2000
2003
EL fuel oil
and machinery is constantly being put into operation. So, in the
2009
second quarter of 2010, for example, a climate-testing laboratory that simulates various climate conditions between +5째C and +50째C at humidity levels of between 30% and 85% was installed
With a connected wattage of 32 kW, this represents quite a
in the Test Center. Development cycles can be thus shortened and
significant consumption of electricity at the site. In order to
developments carried out with less use of materials. This means a
accurately capture its effect on total energy consumption and
direct saving of resources and energy in the areas involved.
evaluate its actual consumption, a separate electricity meter was installed, from which readings are regularly taken.
Environmental Statement 2010 /// 21
4.4 Emissions
A closer examination of the consumption of solvents in auxiliary materials and materials central to the
By using fossil fuels for heating purposes, further air emissions besides CO2 are emitted at the site. The
process of shoe production shows why our many efforts in the mass production of the ”Copa Mundial”
following emissions due to consumption have been calculated. The trend here consistently follows the
football boot model are only having a slow effect.
consumption of fossil fuels and was already explained in section 4.2. Due to the remaining production of special models and runs with very few pieces, it is difficult to move to water-soluble adhesives and hot-melt processes. Moreover, custom-made models are in part very complex in their individual construction, requiring more use of adhesives than the ”Copa Mundial”
2001 2002 2003
2004 2005 2006 2007 2008 2009
football boot. The move to using alternative adhesive processes when making this model is 90% complete and more efforts in this direction are being made continuously. A product-related breakdown
SO2 [kg]
274
286
233
298
313
194
192
146
164
(excluding solvent waste and solvents used for cleaning purposes) returns the following solvent
CO2 [t]
829
784
851
925
1003 913
873
895
737
emissions in 2009:
NOx [kg]
693
650
723
775
843
788
752
782
634
CO [kg]
894
843
921
997
1083 993
948
976
800
Copa Mundial:
4 g solvents/pair of shoes
Dust [kg]
1.4
1.4
1.2
1.5
1.6
1.1
1.0
0.9
0.9
Special models:
25.1 g solvents/pair of shoes
NMVOC [kg]
55
53
54
61
66
54
52
51
44
Average:
8.6 g solvents/pair of shoes
The objective is to completely eliminate adhesives containing solvents in the production of the Copa boot. Air pollutants are also emitted when electricity is generated. Due to our electricity consumption in 2009
4.6 Waste
there were 368 t (253 g/kWh according to data from the energy provider) of indirect CO2 emissions. The
The waste management concept facilitates good separation of accrued waste ratios. Total waste quantity
proportion of renewable energy in our energy mix is 27.9%.
in recent years has remained at the same level. The target to continually reduce the proportion of waste to be disposed of was again achieved. The recycling ratio, i.e. the amount of waste that is recycled
In future our CO2 emissions will be significantly lower through the use of CO2-neutral natural gas, as
expressed as a proportion of total waste, rose in 2009 to almost 98%. This is especially worth mentioning
described under point 3. The amount of CO2 produced as a result of natural gas consumption of around
because waste from other sites/activities (e.g. exhibitions) is also disposed of at this site. However, since
650 – 700 t will no longer appear in our CO2 balance from 2010.
these quantities are independent of the production process and cannot be recorded individually, a more detailed evaluation is not possible. Our fundamental goal is to at least maintain the current level and
4.5 Emission of organic solvents
therefore follow further measures to improve waste management at the site.
Solvent-based adhesives and pure solvents are used in shoe production. The volatile components are released into the environment through extraction. Total emissions of organic solvents for the year 2009 amounted to 4,459 kg. The limit value of the European VOC guideline and the 31st provision of the German law on pollution control, which had to be achieved by 2007, was 25 g per pair of shoes. We achieved our target to reduce diffuse solvent emissions to 20 g per pair of shoes some years ago. The current value for 2009 is 8.6 g per pair of shoes. Specific solvent emissions have therefore been significantly reduced in recent years.
22 /// Environmental Statement 2010
In 2009, 560 kg of waste requiring verification was disposed of.
Key figures: Solvent consumption/pair of shoes 0g
10g
20g
30g
40g
Emissions of solvents by shoe type adjusted for solvent waste and use of cleaning agents
Waste to recycle
70g/Pair
0t
50g
2000 60g/Pair
2001 2002
Solvents shoes total Solvents Copa
1995
Solvents special models
1996
2004
total allowance
Allowance according to 31st provision of the German law on pollution control: 25g g/pair of shoes
250t
300t
2001 2002 2003
20g/Pair 2009 Value: 8,6g g/pair of shoes
200t
2000
30g/Pair
2008
150t
1999
2005 2007
100t
1998
40g/Pair
2006
50t
1997
50g/Pair
2003
2009
Waste for disposal
2004 2005
10g/Pair
2006 2007
0g/Pair
2008 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009
2009
Environmental Statement 2010 /// 23
5 Environmental Programme – Objectives and Measures A number of measures have contributed to the continuous improvement of operational environmental protection at Scheinfeld. In coming years, further activities are planned, geared towards our environmental policy, the global targets of the adidas Group and site-specific circumstances. Responsibilities and the methods required are established internally.
Objectives
Measures
Date
Energy management
• Further development of a system for recording consumption and generation of further key figures
Ongoing
Reduce heating energy consumption
• Energetic clean-up of the Schlaraffia warehouse, with a reduction of specific heat consumption by 15% compared to 2009
2013
Increase energy efficiency
• Optimisation of manufacturing processes and methods for better equipment efficiency
Ongoing
Reduce electricity consumption
• Continuing adjustment of hall ventilation and aeration
Ongoing
• Conversion of hot water tanks into sink heaters in washing rooms
Q2 2011
Emissions
• Updating the annual solvent balance sheet
Q1 following year
Complete elimination of solvent substances in Copa production
• Increased use of hot melt technology and water-soluble adhesives
Ongoing
Reduce CO2 emissions by 20%
• Continued development of alternative production technology
Ongoing
• Use of CO2-neutral natural gas for heating purposes
1.1.2010
• Use of different technologies when attaching insoles
Q4 2010
• Ongoing tests and studies on the use of environmentally-friendly substances in the production process (e.g. water-soluble adhesive, hot melt)
Ongoing
• Replacement by laser technology of the exposure procedure in the finishing process when making printing plates for pad printing
Q3 2010
• Use of digital printing technology in the finishing process, thus reducing the use of raw materials in the pre-print process (screen making)
Q4 2010
Waste management
• Recycling of packaging
Ongoing
Stabilisation to the level of 2006
• Adoption of laser processes (less dust)
Q1 2011
Reduce specific production waste
• Shoe manufacture from lasting process to application of the sole without last change (rejects reduction)
Q1 2011
• Reduction in excess TPU from sole application through the use of a new type of last
Q1 2011
Water management
• Installation of a water meter to record consumption in the employee canteen
Q4 2010
Stabilisation to the level of 2006
• Continuous consumption measurement in the kitchen
Further development of the Environmental Management System
• Implementation of an annual environmental day
Ongoing
• Regular training on relevant environmental aspects as part of routine staff training
Ongoing
• Development and creation of instruction guidelines
Ongoing
• Change to a manufacturing step – reduction of fire risk in the grinding of lasting edge
Q4 2010
Noise (in the workplace) Reduce noise levels Input materials Introduce environmentally-friendly raw materials Reduce use of hazardous substances
Risk management – fire protection
24 /// Environmental Statement 2010
Objectives achieved 2006 – 2009 Since the last comprehensive environmental statement, numerous environmental measures have been put into place at the site. Many small steps have contributed to reaching our environmental targets.
Objectives
Measures
Date
Status
Energy management
• Installation of separate gas and electricity meters in the finishing sector
Q3 2007
4
Identify potential for optimisation through an enhanced database
• Continuous recording of consumption and generation of key data
from Q3 2007
4
Q2 2008
4
Reduce general electricity consumption
• Increased employee information and participation to operate economically with energy: “energy year” • Optimisation of cooling equipment in the kitchen
Q4 2007
4
• Analysis of compressed air grids with external support taking into account potential for optimisation
Q4 2009
4
Emissions
• Create an annual solvent balance sheet
Q1 following year
4
Complete elimination of solvent substances in Copa production
• Increased use of hot melt technology and water-soluble adhesives
Ongoing
(4)
• Continued development of alternative production technology
Ongoing
(4)
• Adoption of closed mixing equipment – reduction in the use of solvent-based cleaning agents
Q1 2009
4
• Optimisation of loading amounts and therefore efficient planning of vehicle sizes and journey intervals
Ongoing
(4)
• Ongoing tests and studies on the use of environmentally-friendly substances in the production process (e.g. water-soluble adhesives, hot melt)
Ongoing
(4)
Waste management
• Increased recycling of packaging
Ongoing
4
Stabilisation to the level of 2006
• Increased separation of specific types of waste
Ongoing
(4)
• Product and process optimisation for the reduction of production waste
Ongoing
(4)
• Updating of the management handbook in an IT-supported document, suitable for the intranet
Q4 2009
4
• Information on environmentally-relevant aspects via notice boards
Ongoing
4
• Regular training on relevant environmental aspects as part of routine staff training
Ongoing
(4)
• Development and creation of instruction guidelines
Q4 2009
4
• Training and education of shoemakers
Start 1.9.2008
4
• Education of young workforce in shoemaking
Ongoing
4
• Removal of redundant cooling equipment that contains cooling agents which are not prohibited but are harmful to the ozone
Q2 2009
4
• Change to a manufacturing step – reduction of fire risk in the grinding of lasting edge
Depending on product
(4)
Input materials Introduce environmentally-friendly raw materials
Further development of the Environmental Management System
Increased promotion of young talents Reduction Risk
(4) Target is in operation or is part of a continuing process Environmental Statement 2010 /// 25
6 VALIDATION Deloitte Cert DE-V-0268 Umweltgutachter GmbH Schwannstr. 6 40476 D端sseldorf Germany Michael Sperling DE-V-0097
26 /// Environmental Statement 2010
7 Contact Partner on Environmental Issues If you have any questions or require further information, please contact us at the following address: adidas AG Social & Environmental Affairs World of Sports Adi-Dassler-Str. 1 91074 Herzogenaurach Germany Tel.: +49 91 32 84 â&#x20AC;&#x201C; 0 E-Mail: sustainability@adidas-Group.com Publication of the next Environmental Statement The publication of the next Environmental Statement will be released in August 2013. For 2011 and 2012, the Scheinfeld site will provide updated Environmental Statements.
This Environmental Statement was made with the cooperation of INTECHNICA Consult GmbH, Nuremburg: www.intechnica.eu Design & Photography: Ralf Munker, www.designstudio-munker.de Printed on RecySatin which is produced from 80% recycled fibre.
Environmental Statement 2010 /// 27
adidas Group Global Technology Center Adi-Dassler-StraĂ&#x;e 24-26 91443 Scheinfeld Germany
Members of the adidas Group
Š 2010 adidas AG adidas is a registered trademark of the adidas Group