Designing Out Waste
Mark Shayler and Leigh Holloway
eco3
www.ecothree.com
Designing Out Waste
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Eco-design. Why, What and How?
Focus on WEEE and RoHS
Disassembly Exercise
Support for Designing Out Waste
Peter Gafney
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EcoDesign
Why, What and How?
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Why the Environment?
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Environmental Concerns
• Growing Concern
– Environmental damage
– Stricter regulations
– Customer requirements
– Public perceptions
• Changes in business practice
• Win – win situations
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Changes in Business
Strategies
Environmental Compliance
Environmental Risk Assessment
Sustainable Business Strategies
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Why Products ?
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‘A product is a symbol of a company’s
capabilities.
It is a result of all the decisions made before,
during and after the design phase’
Philips
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Quality
Innovative
High Tech
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Increasingly the environmental
performance of products will also
say something about the companies that
make them
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Why should I look at
EcoDesign?
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What is Driving this Shift?
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Legislation
Waste disposal and clean-up costs
Increasing efficiency
Environmental management systems
Producer responsibility
Customer requirements
Supply chain issues
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Legislation!
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Legislation
• Product-based
– Packaging Regs. 1997
– Packaging Essential Requirements 1998
– Fridge and freezer recycling (removal of CFCs)
2002
– End-of-life Vehicles (ELV) 2000
– Waste Electrical & Electronic Equipment & RoHS
Directives 2003
– Banning of certain substances to landfill
– Recovery of batteries etc.
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Packaging Regs. – Essential
Requirements
• Came into force 31 May 1998
• Require
– Minimal packaging
– Noxious & hazardous substances minimised
– Packaging must be recoverable
– Limits on heavy metal content
– Applies to ALL companies regardless of size and
turnover
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End of Life Vehicles (ELV)
• Requires the recovery and recycling of
vehicles at the end of their life.
• Original manufacturer is ultimately
responsible
• Legislation came into force in the UK 2003
• Material restrictions
• 2005 – European standards for recovery and
recyclability
• 2007 – Take back of ALL ELVs
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Waste Electrical and Electronic
Equipment (WEEE) & RoHS
• UK legislation will be in place by late 2004
• Forces the recovery and recycling of electrical
and electronic equipment
• Restricts certain substances (RoHS)
• Producers are to pay for collection and recovery
• Directive implies the benefits of using ecodesign
principles
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EcoDesign of Energy Using
Products
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Similar to essential requirements in packaging
Requirement to display a logo showing conformity
Require a ‘high level’ of environmental protection
Specific design requirements such as disassembly,
recyclability, energy efficiency to be used where
‘appropriate and feasible’.
• Avoid ‘the undue use of devices, components
materials or substances which present a threat to
the environment….’.
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Supply Chain
• Large companies are taking on the idea of corporate
responsibility
• EMSs are being extended to cover products
– (EMAS II and ISO 14040 & 14060)
• Companies are auditing their suppliers for environmental
compliance
• Many organisations are developing their own design
guidelines and material restrictions and as a supplier you
will need to be able to meet these
• Some customers are even offering price incentives for
‘eco-friendly’ products
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What is EcoDesign?
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Why Focus on Products?
• 93% of production materials are never
used in the final product
• 80% of products are discarded after a
single use
• 99% of materials used are discarded in the
first six weeks
Source: Factor 4
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Up to 80% of a product’s
financial costs are set at
the design phase
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Materials used in product manufacture all
have some sort of environmental impact
•Use materials with less impact
•Reduce materials used
•Make use of recyclate
•Use renewables
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Processing uses energy and
produces waste and emissions
•Use efficient processing routes
•Recycle waste materials
•Use low energy options
•Avoid the use of hazardous
materials
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A product’s use can have very important
effects on its overall environmental impact
•Reduce energy consumption
•Reduce resource consumption
•Increase durability
•Design for maintenance/upgrade
•Use alternative energy sources
•Reduce weight?
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Design changes can increase the economic
feasibility of recovery and recycling
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Every product has an ‘ecological footprint’
They are just different sizes and shapes
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Applied EcoDesign
How to do it ….. successfully!
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Varian Medical Systems
• One-off £25K investment
– Component costs reduced by
– 14% per annum
– Component count reduced by 65%
– Fasteners used reduced by 29%
– Assembly time reduced by 27%
Resulted in a £145k net
saving in the first year
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Continental Teves UK Ltd
• Leading Supplier of braking systems to
UK and European automotive industry.
• Brake calliper redesign:
– 26% reduction in weight
– 42% reduction in production time
– 62% reduction in machining time and 420
tonnes of metal per year saved
• Over £120k net saving per annum
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Fulleon Ltd
Savings
Materials costs
reduced by
11% - £27550
Labour costs
reduced by
34% - £65100
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Conclusions
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A new business agenda is emerging
Much more focus on products
Focus may drive innovation
Ecodesign and innovation isn’t ‘rocket
science’
EcoDesign
Good
Design
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Focus on
WEEE and RoHS
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Background to the Directives
• Rapid innovation and increasingly short product
cycles have lead to huge volumes of relatively
new products being discarded
• WEEE represents a major source of organic
contaminants and heavy metals which are
potentially harmful to the environment
• Potentially recyclable materials are being
landfilled
• Inefficient use of Europe’s remaining landfill
capacity
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Broad Objectives
The WEEE Directive is aimed at:
• reducing electrical waste, increasing recovery
and recycling and minimising environmental
impact
• improving environmental performance of all
operators involved in the life cycle of EEE
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What is a Producer?
• “producer” means any person who,
irrespective of selling technique used,
including by means of distance
communication ……
1. Manufactures and sells his own brand
2. Resells under his own brand
3. Imports or exports
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What items are covered by
WEEE?
• All equipment that is dependent on electrical
currents or electromagnetic fields
– although certain thresholds apply only equipment
with a voltage rating not exceeding 1000V AC and
1500V DC is included
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10 indicative categories
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8.
9.
10.
Large household appliances
Small household appliances
IT and telecoms equipment
Consumer equipment
Lighting equipment
Electrical and electronic tools
Toys, leisure & sports
Medical devices *
Monitoring devices *
Auto-dispensing machines (vending machines, cash
machines, ticket machines)
* Exempt from RoHS requirements for now
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Key Requirements of WEEE
• Set targets for the recovery and recycling of
WEEE according according to category of
product
– Large household and automatic dispensers (1,10):
80/75%
– IT and consumer (3,4):
75/65%
– Others:
70/50
– Gas discharge lamps:
80% (recycled
• No target for medical equipment (8)
• Targets to met by 31 December 2006
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Targets
Category
Description
Recovery
Recycling
1
large household appliances
80%
75%
2
small household appliances
70%
50%
3
IT and telecoms equipment
75%
65%
4
consumer equipment
75%
65%
5
lighting equipment
70%
50%
6
electrical and electronic tools
70%
50%
7
toys leisure & sports
70%
50%
8
medical devices
no target
no target
9
monitoring devices
70%
50%
10
auto-dispensing machines
(vending machines, cash
machines, ticket machines).
80%
75%
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Key Requirements of WEEE
• Collection facilities to be in place from 13 August
2005
– Kerbside, bring schemes, retailer take-back
• Consumers to return WEEE free of charge
• No absolute requirement to enforce separate
segregation of WEEE
• A target collection of 4kg per head of population
to be achieved by 2006
• A new target will be established by 31 December
2008
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Key Requirements of WEEE
• By August 2005 producers should provide
financing for the collection, treatment, recovery
and environmentally sound disposal of WEEE
from private household deposited at collection
facilities
• Products placed on the market after 2005
producers should be responsible for financing
waste relating to their own products
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Key Requirements of WEEE
• WEEE put on the market before 13 August 2005
or ‘historic waste’ is to be financed
proportionately by producers existing in the
relevant market when the respective costs occur
• For a transitional period of 8-10 years producers
can show the costs incurred in the disposal of
WEEE
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Key Requirements of WEEE
• From August 2005 B2B producers should
finance the collection and treatment of WEEE
• For historic ‘B2B’ waste the end-user may be
partially or wholly responsible for the financing
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Requirements of WEEE
• Producers or third parties acting on their behalf
to set up treatment facilities
• Carried out by regulated operators according to
standards
• Treatment/removal of :
– PCBs over 10cm2, LCDs over 100cm2, toner
cartridges, batteries, CRTs
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Timescales
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Common Position text - Dec. 2001
European Parliament Second Reading - April 2002
Conciliation process - completed Oct. 2002
Adoption of Directives - Late 2002
Publication - 13 February 2003
Member States Transposition by 13 August 2004
Producer Responsibility - 13 August 2005
Substance Ban (RoHS) - July 2006
Meeting Recycling Targets - 31 December 2006
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The Restriction of Hazardous
Substances Directive
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RoHS Directive
• A Single Market Directive on the restriction
of certain hazardous materials
• Seeks to reduce the environmental impact
of WEEE by restricting the use of certain
hazardous substances during manufacture
• Complementary to the WEEE Directive
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What is Covered by RoHS?
• From 1st July 2006, the following are
banned - lead, mercury, cadmium,
hexavalent chromium, polybrominated
biphenyls and polybrominated diphenyl
ethers
• Some exemptions exist
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Scope
• All equipment dependent on electrical
currents or electromagnetic fields
• Eight broad categories, plus electric light
bulbs
• All products in the WEEE Directive except:
– Medical equipment and monitoring and
control equipment
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Annex Exemptions I
• Mercury (in some lighting applications)
• Lead in the glass of cathode ray tubes,
electronic components and fluorescent
tubes
• Lead in certain steel, aluminium and
copper alloys
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Annex Exemptions II
• Lead in high melting temperature type
solders
• (Until 2010) lead in solders for servers,
storage and array systems
• Lead in solders for network infrastructure
equipment
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Annex Exemptions III
• Lead in electronic ceramic parts
• Cadmium plating
• Hexavalent chromium in absorption
refrigerators
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Proposed Limits
• It is likely that limits will be set for RoHS
substance
• The current proposals are for percentage
by weight of homogenous material or
discreet component
• Cadmium – 0.01%
• Others – 0.1%
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Servicing of Older Equipment
Article 2.3
“This Directive does not apply to spare parts
for the repair, or to the re-use, of electrical
and electronic equipment put on the
market before 1 July 2006”
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Arms and Munitions
Article 2.3 of the WEEE Directive
“Equipment which is connected with the
protection of the essential interests of the
security of Member States, arms,
munitions and war material shall be
excluded from this Directive”.
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Future Review
• By 1/2005 proposals to include equipment
in categories 8 (medical) and 9 (monitoring
equipment) of the WEEE Directive
• Evaluation of the implications for
– Deca BDE – this is now covered
– Mercury in straight fluorescent lamps for
special purposes
– Lead in solders for servers etc.
– Light bulbs
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Timetable
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Conciliation – concluded October 2002
Final text approved – December 2002
Publication in OJ – January 2003
UK legislation in place – July 2004
Substance bans – 1st July 2006
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Implications for Design
• WEEE
– Weight
– Disassembly
– Recyclability
– Removal of items requiring pre-treatment
– Labelling
– Wider re-design opportunities
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Implications for Design
• RoHS
– Identification and replacement of proscribed
substances
– Design implications – product
– Design implications – process
– Compatibility between alternative solders
– Functionality – is it over-egged?
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3
e
toolkit
• Compliance check
• Obligation calculation
• Training materials
• Interactive guides
• Lead-free section
• Quizzes
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3
e
toolkit
• Video industry views
• Materials declaration
forms
• Supply-chain actions
• Where to find RoHS
proscribed materials
• Alternatives
• DIY testing kits
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Disassembly Exercise
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Group Work
Electronics
• Take them apart carefully
• Examine
– Packaging
– Fixings
– Materials
– Labelling
– Ease of disassembly
– Opportunities for:
• Simplification
• Modularity
• Reuse
• Servicing
– Ease of compliance with WEEE/RoHS?
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Group Work
• Other products – focus on packaging
– Type and mix of materials
– Does it do its job?
– Could it be simplified?
– Implications for Essential Requirements and
Recovery costs?
• Feedback
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3
eco
info@ecothree.com
01455 213322
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