Verallia

18, avenue d’Alsace

Les Miroirs - 92096 La Défense Cedex
Tel. +33(0)1 47 62 38 00
Fax +33(0)1 47 62 39 55

www.verallia.com the many lives of glass

sustainable development:
a corporate philosophy
Verallia aims to become the benchmark
for glass packaging and, more generally,
for rigid packaging – a company contributing
to the sustainable development of its
communities, value for its customers
and the well-being of its end-consumers.

1
 • Our key figures 4
• More than promises... commitments 6

A Material with Unparalleled Virtues 10

• The three stages of glass production 14

the Environment: our everyday focus 16

• Incorporating environmental factors and anticipating risks 18

contents
4 key priorities :
Increased use of recycled glass
Reduced CO2 emissions
Improved energy efficiency of our processes
Optimized use of water resources
Reduction of other atmospheric emissions
From waste to raw material
• Anticipating environmental risks 30

Eco-Conception: Delivering Customer Satisfaction 32

• Our eco-conceived product ranges 34

verallia: A responsible employer 36

• A zero-risk culture 38
• Two objectives for optimal working conditions 40
• People: our key resource 42
• Audits: as transparent as glass 48

acting locally 50
• Endlessly recyclable 52
• Community outreach 54
2
 Still wines

29%
Sparkling wines

9%
Spirits
sales by market 10%

our key figures Beer

19%

sales by region Food

19%
United States

31%
Other bottles

8%
Approximately 15,500 employees in 14 countries
Portfolio of more than 10,000 customers Other (including
Eastern tableware

Approximately 25 billion bottles and jars produced in 2011

Europe and decoration)
Western
4% Europe 6%
56%
Sales presence in 47 countries 13 awards for innovation in 2011 South
America

9%
95 glass furnaces and 6 centers for research & development and innovation 5
more than promises… 1. Comprehensively and strictly apply our Principles of Conduct:

commitments
Professional Commitment, Respect for Others, Integrity, Loyalty and Solidarity

and action:
Respect for the Law, Caring for the Environment, Worker Health and Safety,
and Employee Rights

2. Pursue an ambitious policy to constantly

improve workplace health and safety

3. Continuously encourage the personal

development of our employeeS, with a special
focus on diversity, training and career management

6 7
 5. Minimize the environmental footprint of our operations
with four priorities:
• Maximum use of recycled glass in our furnaces
• Increased energy efficiency in our manufacturing processes
• Reduction of CO2 emissions
• Optimized use of water resources

6. Implement alternative energy solutions at our plants

through research and development focusing on green electricity, biogas
and syngas (synthesis gas) produced from biomass

7. continuously develop eco-conceived products,

4. Be a responsible and sustainable player within creating additional value for our customers’ products
our local communities, notably through the promotion
of glass recycling and the enhancement of awareness of all aspects
of sustainable development

8 9
a material with unparalleled virtues
GLASS: THE IDEAL PACKAGING CHOICE
Glass is unbeatable when it comes to
sustainable development. Made from natural
raw materials, glass is fully and endlessly
recyclable in a closed-loop process (100% of
glass collected can be recycled, over and over
again). Glass packaging is an inert, neutral
material which blocks the migration of
chemical toxicity to its contents. Glass
is also the only food and beverage packaging
material in which the content is not in contact
with a plastic film, a material derived mainly
from petrochemicals which can adversely
impact products as a result of leaching.
Glass is thus the ideal packaging choice for
10
maximizing the value of the product, while
protecting the health and well-being of
consumers and ensuring 100% recyclability.
These qualities make glass a material
for the future, offering a perfect response
to increasingly responsible consumption
patterns.
Glass is viewed by customers and end
users as a healthy choice with impeccable
green credentials that ensures optimum
product quality. In public opinion surveys
commissioned by industry associations in
Europe and the United States, glass frequently
emerges as the preferred packaging material
among consumers. It is perceived as a safe,
healthy, pure, neutral material with excellent
aesthetic qualities and environmental
benefits (including full and endless
recyclability).
According to the European Container Glass
Federation (FEVE), 84% of people in Europe
would like to see more widespread use of
glass packaging; 70% would like to buy more
products in glass containers; 42% are prepared
to pay more for glass packaging; and 82%
want companies to use more glass packaging.
In the same study, 88% of people believed that
glass is safer than plastic in terms of health.
11

a material with unparalleled virtues
IT’S GOOD
TO HAVE FRIENDS
In Europe, FEVE has created “Friends of Glass,”
a consumer forum with a strong presence
on the internet and among social networks. It
promotes the qualities of glass packaging,
including its purity and food safety benefits
as well as its environmental advantages.
In October 2010, in partnership with
national glass industry associations, FEVE
launched the “Nothing” publicity campaign
in 12 European countries (France, Germany,
Poland, the United Kingdom, Italy, Greece,
Austria, Czech Republic, Switzerland, Spain,
the Netherlands and Slovakia).
The accompanying website
(www.nothingisgoodforyou.com) outlines
the reasons why glass is the best and safest
packaging material and offers consumers the
chance to order a free sample of “nothing” in
the form of a beautifully crafted bottle or jar.
Simultaneously with the campaign launch,
Friends of Glass published a survey conducted
in 19 European countries by the market
research firm TNS.
12
virtues of glass
MAJOR BRANDS
CHOOSE GLASS
Many leading food brands use glass
containers for their dairy products because
of the material’s chemical purity, its ability
to preserve taste and freshness, and its 100%
recyclability.
It was precisely these properties that led
Yoplait to switch to glass jars designed by
Verallia for its “Saveurs d’autrefois” range
of artisanal yogurts. The natural advantages
of glass, as well as its recyclability, played
a key role in Yoplait’s decision. In the United
States, Traders Point Creamery now also
packages its cheese products in glass
rather than plastic. The elegant new
jars, manufactured by Verallia France
and sold by Verallia North America,
keep the product fresh and
attract the attention
of potential buyers.
A COMPETITION TO CREATE THE DIFFERENCE
Verallia has formed partnerships with
design schools in a number of countries to
in September 2011. Students were invited to
explore the creative, technical and marketing
foster a greater understanding of glass among potential of glass, around the theme of
future designers and to promote it as “Create the Difference.” The most innovative
a state-of-the-art material with great entries in terms of form, presentation,
aesthetic potential. decoration and content enhancement will
In France, for example, following be awarded one of the three top prizes. The
the success of the competitions held in competition is now sponsored by well-known
the previous two years, Verallia launched its designers who are committed to green design
3rd annual Design and Packaging competition and sustainable development.
GLASS IN ACTION
In all of its countries of operation around industry associations or directly by Verallia, is a member of the Glass Packaging Institute
the world, Verallia actively supports are designed to encourage consumers (GPI), the voice of the North American glass
communication campaigns that promote to recycle and provide information on the industry.
the qualities and capabilities of glass among purity and environmental benefits GPI runs the “Keep it Organic” website
consumers as well as opinion leaders in the of glass and its ability to preserve product (www.keepitorganic.org) to promote the link
packaging industry. taste and quality. between glass packaging and organic food
The campaigns, which are driven either by In the United States, for example, Verallia and beverage products.
13

a material with unparalleled virtues
the three stages of glass production
The process for manufacturing glass packaging requires 2. The “hot end:” forming
and treatment of the glass
the mixing of various ingredients and the heating of them in
The molten glass is then conveyed from
furnaces to produce a liquid that can then be shaped using
the furnace via a series of distribution
special techniques (known as the “blow and blow” and “press channels (or “feeders”) to the forming
and blow” methods). machines at a temperature between 1100°C
and 1250°C (2000°F and 2300°F).
The forming process transforms the
compact mass of glass into a hollow shape,
1. Melting the mixture of raw materials
(sand, soda ash, limestone, feldspar, etc.)
using a metal plunger and blown air (known
as the “press and blow” technique) or via
and recycled glass (cullet) two blowing stages (known as “blow and
After mixing, the raw materials and cullet blow”).
are melted in furnaces at a temperature Before entering the forming machines,
of approximately 1550°C (2800°F). It the glass flow is cut into “gobs” whose
takes approximately 24 hours for the weight, shape and temperature are precisely
raw materials entering the furnace to be controlled.
converted into molten glass. The extremely The gob is then transformed by pressing
high temperatures involved mean that it is or blowing into an intermediate hollow
more efficient for the furnaces to operate pocket shape in a blank mould, before
continuously—24 hours a day, seven days being transferred to a finishing mould for
a week. blowing into the final shape of the bottle
or jar. This two-stage process lasts just a
few seconds, after which the products are
at a temperature of approximately 600°C
(1100°F).
14
the manufacturing process
To strengthen the glass containers, they
then undergo reheating and gradual cooling
in a long, flat oven called an annealing lehr.
Annealing takes between 50 minutes and
2 hours, depending on the type of container.
The containers are also given two surface
treatments to make them more resistant
to scratches: a very fine coating of tin oxide
is applied to the glass while it is still hot,
and a layer of wax is sprayed on once
the glass is cool. The treatment products
employed are compatible for use with food
and beverage packaging.
The batch house is where Cullet (crushed recycled
1 2 4 The regenerator chambers
6 The forehearth brings 7 The gobs are delivered 9 The annealing lehr reheats
sand, soda ash and glass) may compose up capture the heat from the temperature of the to moulds on a forming the glass to approximately
limestone are weighed and to 90% of the batch mixture. the flue gases and cycle the molten glass to a uniform machine known as an 570°C (1050°F) and then allows
mixed with other raw materials It consists of post-consumer heat back to preheat the level. Shearing and distribution individual section (IS) machine, it to cool gradually. This process
to create the batch mixture. glass as well as glass recovered combustion air up to 1300°C systems cut the molten glass where the glass is shaped reduces stress in the containers,
and recycled within the plant (2400°F). from the forehearth into mechanically by pressing thereby promoting the natural
as part of the quality assurance uniform gobs, which are then and/or blowing with strength of the glass.
5 The furnace melts raw
procedures. transferred to the forming compressed air.
materials to form glass. 10 Cold-end coating is also
machines.
3 The furnace control Each furnace supplies glass A hot-end coating is then applied to the exterior of
8
console allows the to several production lines. applied to the exterior the containers to reduce the
1 operator to monitor and control Glass temperatures inside the of the glass containers to coefficient of friction of the
5 the furnace and the batch furnace are typically between strengthen the glass and act as glass (to make it more slippery),
house operation. 1250 to 1500°C (2300°F to a base coat for the subsequent which helps to prevent
2700°F). 10 cold-end coating. scratching.
6
3 11 In the fast-cooling
9 section, the glass cools
to a temperature that allows it
to be handled.
4
12 Specialized on-line testing
equipment, including the
Manufacturing 7 squeezer, plug gauger, thin-wall
tester and check detector, as
glass bottles 2
8
well as physical and visual
inspections, are used to ensure
and jars product quality. Any container
that does not meet quality
standards is rejected and
returned to the furnace to be
recycled as cullet.
13
12 13 The containers are then
stacked between five and
11 15 layers high on pallets made
from repaired or recycled
materials.

3. The “cold end:” inspection
and packaging of the glass containers
The quality control processes applied depend
on the target market and the products
concerned. Mechanical, video and light beam
technology, as well as visual inspections, can
be used to check the neck area, wall thickness,
dimensions and appearance.
Any rejected containers are removed
from the production line and recycled as
cullet for making new glass. After exiting
the production line, finished products are
generally packed on pallets, or (in the US and
Germany, in particular) in cardboard boxes or
plastic crates.
A FOCUS ON our environmental responsibility
CONTINUOUS
IMPROVEMENT
At Verallia, we are committed to continuously
improving our industrial processes and
facilities. As a result of our in-house glass
furnace design capabilities (in particular our
engineering center in Chalon-sur-Saône, as
well as facilities shared with Saint-Gobain,
notably Saint-Gobain Conceptions Verrières)
and our ability to manufacture forming
machines, we are able to incorporate new
developments into our industrial facilities on INCORPORATING ENVIRONMENTAL FACTORS
an ongoing basis.
AND ANTICIPATING RISKS
Some of our facilities in 14 countries around Our company is committed to protecting
the world are situated in densely populated the environment through a series of
areas, while others are located away from programs and initiatives encompassing waste
population centers (for example close to our management; water treatment; reduction
customers in wine-producing regions). of energy consumption, CO2, and other
We are committed to protecting this wide atmospheric emissions; and participation in
range of environments. projects to separate and sort post-consumer
We aim to: glass in Europe and the United States.
1. I ncorporate environmental factors into These actions are backed by major
every stage of our activities investments, with almost €200 million
2. Anticipate environmental risks devoted to health, safety and the environment
between 2004 and 2011.
17
 recycled glass
environmental responsibility

4 key priorities
I ncreased use of recycled glass

R
 educed CO emissions
2

the environment: I mproved energy efficiency of our processes In accordance with the Health, Safety, Environment and Quality charter
implemented at our sites, new plant construction and major expansion projects

our everyday focus

require an environmental risk assessment before they can proceed. An initial
environmental survey encompassing air, water, and soil quality and biodiversity is
O
 ptimized use of water resources conducted with the support of experts as well as local consultants who work across
all of Verallia’s activities. This survey then serves as a baseline for the sites concerned.

1. Increased use of recycled glass The proportion of recycled glass that

The aim of our environmental policy—a key part of our sustainable in manufacturing
development program—is to preserve natural resources and continuously The use of recycled glass (in the form of
reduce the environmental impact of our activities. We also take action cullet) in the glass manufacturing process
brings major environmental benefits. It
to reduce emissions of nitrogen oxides (NOx), sulfur oxides (SOx) and dust, boosts energy efficiency and reduces CO2
and to control risk by means of proven environmental management systems. emissions, since for each additional 10%
of glass cullet that goes into our process we
use 3% less energy and produce 5% less CO2.
Using recycled glass in our furnaces also
means that we consume fewer natural
resources, since the cullet takes the place
of the natural raw materials used to make
glass (sand, limestone and soda ash).
Recycling one metric ton of cullet enables us
to save an average of 1.2 metric tons of raw
materials.
goes into our furnaces has increased
significantly in recent years as a result
of highly effective recycling programs in
some countries and the development
of more efficient processes in countries
such as the United States.
Some furnaces, such as those at Oiry
(France), Montblanc (Catalonia, Spain) and
Milford (Massachusetts, United States) can
handle up to 95% cullet.
Recycled glass usage is a key
performance indicator for production
facilities and is tracked on a monthly basis
using our industrial reporting system.

18 19

72% o
 f glass
packaging
produced
in Europe
TECHNIQUES FOR IMPROVINg
ENVIRONMENTAL PERFORMANCE
Life cycle assessment (LCA) is a technique for assessing the environmental impact
associated with all stages of a product’s life cycle.
An environmentally responsible company
needs a clear understanding of how its
activities affect the environment throughout
the life cycle of its products. LCA is a technique
that enables companies to achieve this
objective by quantifying the environmental
impact of every stage in a product’s life,
from extraction of raw materials, through
the distribution and use phases, to disposal
or recycling in the end. LCA is a highly
sophisticated multi-criteria assessment
technique that has become recognized as the
standard in the field.
20
The life cycle assessment (LCA) encompassed
72% (by volume) of glass packaging produced
in Europe and 75% of glass packaging
produced in the United States. It
enabled us to identify our key
environmental priorities.
75% of glass

packaging
produced
in the United
States
LCA is a key component of our sustainable
development program. It is used as a decision
support tool that enables us to:
• identify priority areas of focus
• ensure that implemented actions deliver
significant environmental benefits and
check that individual actions do not result
in pollution being transferred from one
impact category to another. (The use of
industrially decarbonated raw materials,
for example, might seem like a good idea,
but would merely involve shifting CO2
emissions to our suppliers with a negative
net impact on the environment, since the
product life cycle would then involve two
separate heating processes.)
CO 2 emissions
ENVIRONMENTAL
DASHBOARDS:
MONITORING
PERFORMANCE
AT THE PLANT LEVEL
To ensure that our
environmental actions
are deployed with
the necessary depth
and breadth, we have
introduced a system
2. Reduction of CO2 emissions We have been working to reduce these
of “dashboards” that
The CO2 emissions that result from our emissions for several decades now,
enables each production
site to assess its
industrial activities occur at different stages in
the product life cycle:
using three primary methods:
• Continuously increasing the percentage
performance against • The extraction or production of certain raw of recycled glass (cullet) used in place
a set of key indicators materials, for example synthetic soda ash, of new raw materials in glassmaking
(energy consumption; mainly used in Europe and South America, furnaces
use of renewable energy; generates CO2 emissions. • Reducing the consumption of energy
CO2, nitrogen oxide • The decomposition of raw materials in from fossil fuels
(NOx), sulfur oxide (SOx)
glassmaking furnaces, in particular • Reducing electricity consumption
sodium carbonate and limestone, may
and dust emissions;
also produce CO2.
water consumption; • Greenhouse gas emissions also result from
waste recycling; and energy use through:
With these goals in mind, LCA was use of cullet). The - direct emissions from fossil fuels
introduced to the glass packaging industry goal is to use this (oil and natural gas) used in the melting
in 2007: industrial performance and forming stages of the process, or
• in the United States by the Glass Packaging assessment tool as a - indirect emissions from the generation
Institute (GPI - www.gpi.org), of electricity used in our facilities.
platform for identifying
• in Europe by the European Container Glass • Other phases in our product life cycle
best practices and
Federation (FEVE - www.feve.org). (such as transportation, secondary and
implementing tertiary packaging, pallet production, etc.)
operational are also likely to generate greenhouse
improvement plans. gases.
21

environmental responsibility
3. Improving the energy efficiency
of our processes
We are taking steps to reduce our energy
consumption in a number of key areas
by optimizing the operation of our furnaces
and leveraging technological innovations.
Optimizing furnace operation
In 2008, Verallia launched a world-class
manufacturing program at its plants.
Dubbed E² (Enterprise Excellence), the
program aims to make us more efficient
by continuously improving our industrial
processes.
The key areas of focus of the E² program
are organization, improvement of facilities
and elimination of waste.
E² also aims to foster a culture of
excellence among our teams in order to
optimize performance and competiveness
through the adoption of best practices. This
will enable us to meet the expectations
of our customers and all stakeholders more
effectively. The E² program is based on
22
seven continuous improvement indicators:
quality, flexibility, team commitment,
availability, workplace safety, environment
and innovation.
One of the workflows of the E² program
involved looking at ways to reduce the
energy consumption of our furnaces. The
first stage involved identifying waste. The
work groups then focused on operating
conditions, and in particular optimizing
moisture control, excess combustion air
and glass temperature. Individual parameter
adjustments were tested at pilot sites
to assess the potential benefits.
As a result of the analyses conducted
within the scope of E², a furnace operation
and maintenance optimization program
was launched in 2010. Production managers
at each site carry out precise monthly
monitoring of furnace energy consumption
and compare the results with expected and
past consumption levels. Furnace operation
can then be adapted to ensure that
energy consumption is optimized. Energy
energy efficiency
performance data obtained using this
method, known as “energy gap analysis,”
is fed into a comprehensive reporting
system that enables cross-comparison
of performance at different sites in a given
country. The program is currently being
rolled out to all Verallia plants in Western
Europe, the United States and Latin
America, and will subsequently be extended
to cover Eastern Europe and Algeria.
When our glass furnaces are rebuilt,
which happens every 10 to 14 years, we
systematically install the most energy-
efficient furnace technology available.
O
 ptimizing the use of compressed
air in production facilities
The manufacture of our bottles and jars
involves a number of pneumatic devices
that operate using compressed air, which
is produced using electricity. Forming
machines (also known as IS machines)
are among the largest consumers
of compressed air. The pressure of the
compressed air can be optimized to
precisely meet a machine’s requirements,
thereby delivering savings in electricity
consumption. Although this approach has
already been successfully adopted at some
Verallia facilities, the quantity of energy FURNACE RECONSTRUCTION BRINGS
consumed in compressed air production still
needs to be reduced at other sites. Metering
IMPROVEMENTS AT SAPULPA
systems are being put in place to allow In 2011, one of the end-port furnaces at Verallia North America’s Sapulpa facility was rebuilt,
compressed air pressure and consumption providing the opportunity to implement a number of significant technological and process
to be adapted to the specific needs of improvements, including state-of-the-art burners incorporating the latest advances in
each of our sites. Energy consumption for combustion technology (relating to air velocity and angle), as well as individual injector control.
compressed air production accounts for up These improvements, designed to ensure a more consistent flame and hence better combustion
to 6% of the total energy consumption of a control, have delivered a 35% reduction in the energy consumed by the furnace.
glassmaking plant and almost 40% of the Process improvements included the publication of a user guide to support furnace operation,
total electricity consumption. together with information on burner settings and energy use.
Verallia is working to reduce the amount
of energy we consume in producing
compressed air. Our target is a reduction of
approximately 7% in electricity consumption
(excluding melting).

23
r energy efficiency
environmental responsibility
RENEWABLE ENERGY
In addition to its work to reduce reliance
on fossil fuels, Verallia is partnering with
potential suppliers of renewable energy,
and in particular biomass, with the intention
of using renewable energy to power glass
furnaces. The use of biomass energy reduces
fossil CO2 emissions from glassmaking plants,
and also helps reduce other environmental
impacts on the surrounding area through
the beneficial re-use of waste products.
In a further reflection of Verallia’s
engagement on this issue, the company
is leading a research and development project
with GDF Suez, Xylowatt, Cirad and CIVC,
with support from the French National
Research Agency, to promote the use
of vineyard biomass in the glass melting
process in the Champagne wine region.
The ultimate goal is to speed up the process
24
of replacing fossil fuels with renewable
energy sources derived from wine production.
The objective of the project, titled BioViVe
(from the French for “Vineyard biomass for
glass melting”), is to replace fossil fuels used
in gas-fired furnaces with a synthetic gas
(or syngas) obtained from wood by-products
of vine pruning and uprooting activities.
The Champagne wine-producing region
boasts as-yet untapped biomass resources,
such as vine prunings, which are currently
burned in the vineyard, and uprooted vines.
The BioViVe project is adapting existing
wood gasification technology used in forestry
applications to the characteristics of vine
wood and optimizing the syngas obtained
for use in a glassmaking furnace. The vines
that produce Champagne will also generate
part of the energy needed to manufacture
the bottles in which they will be packaged.
Alongside their research work into syngas,
the project partners are also planning to set
up a local, sustainable biomass collection
network with local winegrowers.
When the development stage of the
BioViVe project is complete, 7% of the
fuel required for the glass furnace at Oiry
(Champagne region) will be replaced with
syngas on a trial basis. The ultimate goal
is to develop the process and associated
infrastructure to a level where up to 50%
of the furnace’s fuel needs can be met
with syngas.
Successful completion of the project on
an industrial scale will save 10,000 metric
tons of CO2 emissions per year in the
Champagne region, equivalent to the exhaust
emissions from approximately 5,000 vehicles.
In addition to its R&D work on vineyard
biomass, Verallia is investigating the
possibility of using biogas from the
fermentation of non-wood biomass as an
energy source for its glass furnaces. Tests
carried out at our plant at Bad Wurzach,
Germany, have shown that energy
substitution rates of around 10% could be
achieved under certain conditions. Work is
ongoing to adapt the characteristics of the
biogas to the requirements of glass furnaces
and boost potential energy substitution rates.
Reducing reliance on fossil fuels
through targeted R&D activities
Alongside its continuous improvement
program, Verallia is working on a range
of research and development (R&D)
projects aimed at optimizing processes and
developing innovative solutions to reduce
energy consumption. The company works
in close partnership with Saint-Gobain
Recherche and has developed a number
of partnerships with startup companies.
For example, research into feeders Another target area is the electricity
(the distribution channels used to equalize consumption of annealing lehrs (in which
the temperature of the glass and convey the bottles and jars are strengthened by
it to the forming machines) is focused on being reheated and gradually cooled), which
the development of a new feeder concept we are aiming to reduce by optimizing the
designed to ensure that the glass is at applied temperature profile. This work could
a more uniform temperature, thereby eventually deliver a substantial reduction
reducing energy consumption. in energy consumption.
Work is also underway to optimize
the ventilation system used for cooling
the forming moulds on IS machines, with
the aim of delivering a further reduction
in electricity consumption.
25

environmental responsibility
 ptimized use of water resources
4. O
A certain quantity of natural resources must
be used as part of the glass production
process. Water, for example, is an important
resource, which we use mainly for
cooling installations that operate at high
temperatures. However, 17% of our sites
are located in “water stress” zones.
To limit the volume of water we extract,
we use closed-loop systems at our industrial
facilities whenever possible. Where a
closed-loop system is not in place, water
is systematically treated before being
discharged into the environment.
Our Figueira da Foz plant in Portugal,
for example, reduced its water consumption
by 20% between 2008 and 2011 as a result
of the implementation of a number of best
practices, such as the use of a rainwater pond
to allow water to be reinjected into the water
system of the manufacturing process;
the installation of a series of valves to
26
water
control the water flow injected for cooling
the “gob” of molten glass after it has left the
furnace; and water temperature monitoring
throughout the water system.
The Albi plant in France, operated by
VOA, also reduced its water consumption by
30% between 2010 and 2011 after a detailed
analysis of the condition of buried piping at
the plant identified several defective pipes
and a number of significant leaks.
We are currently developing a sustainable
water management policy which will be
gradually rolled out to all sites with the aim
of minimizing the impact of our activities on
water resources.
REDUCTION OF OTHER ATMOSPHERIC EMISSIONS
We are also working to limit atmospheric
emissions other than CO2, in particular
nitrogen oxides (NOx) resulting from
the oxidation of combustion air at high
temperatures; sulfur oxides (SOx) arising
from the oxidation of sulfur contained
in the fossil fuel used to heat our glass
furnaces (mainly oil) and from sulfates
contained in the furnace batch material;
and dust, for which we aim to achieve
levels that go beyond those required by
national regulations.
Primary emissions reduction measures
applied to our furnaces over the past
20 years have reduced NOx emissions due
to combustion by almost half, as well
as delivering a significant reduction in
SOx emissions (in combination with the
use of low-sulfur fuel oil).
The company has made significant
investments in furnace equipment such as
electrostatic precipitators to treat gaseous
effluent and bring very significant reductions
in dust emissions. All of our plants in
Western Europe and Brazil have installed
electrostatic precipitators, and the systems
are currently being deployed at our plants in
the United States.
Recent years have seen significant
reductions in emissions at all of our sites.
In the period 2004-2011, dust emissions fell
by 50%, NOx emissions by 20% and SOx
emissions by 9%.
Finally, our research and development
teams are now developing an innovative
combustion technique designed to
significantly reduce NOx emissions
generated during the manufacturing process.
27
 recycling process

all about
SORTING

Sorting is the term

used to describe the
separation of colored
glass from clear glass
by optical means.
Glass retains its color
after recycling, so it
is not possible
to make clear glass
from unsorted
waste glass.

more recycling
The majority of our industrial sites have
temporary waste storage facilities, where
waste is sorted by type before removal.
The ultimate goal is to reduce total waste
volumes and to re-use or recycle all of
less WATER CONSUMPTION
The most water-intensive stage of our
product life cycle is the production of soda
ash, used as a raw material in glass furnaces
in Europe and Latin America. The use of cullet
in glass production reduces the quantities of
our waste, with no waste going to landfill.
Verallia Deutschland currently recycles
more than 90% of the waste produced by
its plants.
raw materials required (including soda
ash), thereby significantly reducing
water consumption and diminishing
the environmental impact of our product
life cycle.
FROM WASTE TO RAW MATERIAL
Recycled glass is processed to make it suitable
for use as the main raw material in our glass
production process. Non-glass materials—
which make up 5-10% of the material
collected, and can negatively affect product
quality and reduce furnace lifetimes—are
removed and partly recycled. For example:
•  Opaque, non-meltable mineral materials
such as stones, porcelain, ceramics, etc.
are detected using optical techniques
and removed.
•   Magnetic metals are separated by loading
the glass onto a conveyor belt equipped
with a powerful permanent magnet
and sent for treatment and recycling.
•  Non-magnetic metals are removed using
eddy current separators, before being sent
for treatment and recycling.
•  Soluble organic materials (food residues)
are removed by cleaning and sent for
composting.
•  Insoluble organic materials such as paper
labels, fragments of cardboard, plastic,
etc., are removed by manual sorting and
suction/blowing.
•  Organic materials are then dispatched
for appropriate waste management
(for example plastics treatment/recycling).
Other treatment options are also available,
such as optical color sorting to optimize
cullet recycling.

28 29
 prevention
environmental responsibility

anticipating environmental risks

Verallia’s industrial risk management policy has three complementary areas of focus: Assessing the results of continuous improvement

1. Prevention improvement programs. 3. Anticipation Regular environmental audits and monitoring audit and has to be renewed on a regular
• Managers at our plants • Training and awareness Our Business Continuity programs are conducted throughout basis. The key requirements of ISO 14001
are issued a prevention programs are deployed Plan is designed to allow our projects to enable us to evaluate our are also checked for compliance during regular
manual with the rules to help our personnel the company to manage environmental performance and develop 20-stage internal audits carried out by audit
and guidelines that apply implement best practices. crises effectively and return improvement plans. Our continuous teams from other Saint-Gobain businesses.
to design work as well as to normal operations improvement program—an important area In 2011, the company launched a new
operational management. 2. Protection under optimum conditions. of focus for Verallia—has helped us to internal environmental audit system to
• Annual audits by an We have an annual Regular exercises are significantly reduce the environmental assess compliance with the various standards
Prevention is the key principle behind the environmental external body, as well investment program conducted to test our impact of our activities in recent years. applied within the company. European sites
policy we apply to our industrial operations. as self-assessments, designed to improve safety emergency plans and We are developing an environmental will be the first to implement the system.
help glassmaking sites at our plants (new layouts, provide plant personnel management system at our sites based on We are committed to upgrading our
We put this preventive approach into practice by: to prioritize actions and hazard detection, sprinkler with hands-on experience the ISO 14001 standard governing continuous production facilities in emerging countries. protection at production sites. The Zorya plant
• Using processes whose environmental impact has been fully evaluated measure progress within systems, etc.) in operating under degraded improvement of environmental performance. Acquisitions in some countries generally in Ukraine is one example. It was acquired in
the scope of continuous conditions. ISO 14001 certification is issued by an require a non-recurring capital expenditure 2006 and gained ISO 14001 certification
• Designing increasingly safe, reliable and efficient equipment
approved independent body following a site to improve safety and environmental in 2009.
• Maintaining our plants effectively
• Using monitoring and testing equipment (for example to detect leaks)

30 31
eco-conception: delivering
customer satisfaction
THE ENVIRONMENT MATTERS
We believe that reducing the environmental
impact of our activities, when combined with
proactive recovery and recycling of glass,
makes glass packaging a more attractive
proposition for consumers. This is the rationale
behind our eco-conceived product lines.
Our manufacturing process for glass
packaging allows us to offer our customers
added-value products that are attractive
to consumers, and to reduce environmental
impact throughout the product life cycle,
from raw materials to the end user
(including selective sorting of glass after use)
and, finally, recycling.
By optimizing the weight of glass required
to produce a container of a given shape,
our eco-conceived products are particularly
environmentally friendly. And, like all of the
glass packaging products manufactured
by Verallia, they benefit from the inherent
qualities of glass—a neutral, inert material that
is fully and endlessly recyclable—as well as the
improvements that we are making
to the glassmaking process (optimized energy
efficiency of production equipment, increased
use of recycled glass in furnaces and reduction
of CO2 emissions associated with raw materials
extraction, production and shipment).
Eco-design is now a key element
of our sustainable development policy.
Consideration of environmental factors
is a matter of daily concern in our design
offices and production plants, and our
technical teams have fully embraced the
principles of environmentally-friendly
design. To support the eco-conception
process, Verallia is developing tools to
optimize the shape of glass packaging,
reducing total weight without loss of
strength and ensuring that we showcase
our customers’ products.
33

eco-conception: delivering customer satisfaction
our eco-conceived product ranges
In 2011, Verallia sold more than 1.6 billion eco-conceived bottles under the
Ecova and ECO Series™ names, for a total of 2.9 billion bottles sold since the
ranges were launched in 2009.
Our eco-designed ranges were successfully
rolled out in 2009, mainly under the Ecova
name (ECO-friendly and VAlue), in France,
Spain, Argentina, Chile, Brazil, Portugal
and Italy, and under the name ECO Series™
in the United States.
These containers, which combine aesthetic
qualities with optimized weight while
enhancing customers’ products, are intended
for the still and sparkling wine and beer
segments. They are tailored to the needs
of regional markets in each country by local
sales and marketing teams.
In 2011, for example, the Vins du Jura trade
association in France decided to change its
standard bottle, created in 1976, to help raise
the profile of its product and demonstrate its
commitment to sustainable development.
34
ecova and eco series tm
Teams from Verallia France worked closely
with key customers within the trade
association to develop a customized Ecova
model that met ambitious specifications
in terms of shape, weight and eco-design
features. The new bottle, branded “Ecova -
Vins du Jura,” offers a number of advantages,
including optimized weight (reduced from
600 to 540 g), an attractive shape that
highlights the qualities of the product,
and a visible, distinctive design that
reflects the spirit of the Jura region.
The Lirac wine trade association has
also chosen an Ecova bottle manufactured
by Verallia France for its wines, which are
produced in just four villages in the Southern
Rhone Valley. The new Burgundy-style bottle
bears a special emblem on the shoulder.
The new bottle expresses a combination
of respect for the historic traditions
of the great Côtes du Rhône wines with
a touch of freshness from the distinctive
design. By choosing the Ecova design,
Lirac is demonstrating its commitment
to “eco-citizenship,” while also giving its wine
a differentiating edge over other appellations.
In Brazil, Verallia also launched four
specially designed 1.5-liter Ecova bottles
in 2011 to meet the needs of the local wine
market. Available in both Bordeaux
and Burgundy styles, the new bottles have
been a commercial success with several
leading wine companies, including Garibaldi,
Aurora and Fante, as a replacement for
packaging materials such as PET and BIB
(“bag-in-box”).
RETURNABLE BOTTLES
Supporting the move toward returnable
glass bottles, Verallia is developing a new
generation of mineral water bottles for its
customers.
In Germany, for example, the company
has designed innovative new bottles for
Gerolsteiner and Münsterländer Salvus
Mineralbrunnen, meeting market demand
and sending a strong signal that glass is
making a comeback in the mineral water
segment.
The new 1-liter bottle designed for
Gerolsteiner, available in packs of six, has won
two design awards: the silver medal in the
non-alcoholic drinks category of Lebensmittel
Praxis magazine’s “products of the year”
awards, and the innovation prize from
German environmental association Deutsche
Umwelthilfe (DUH) and the Stiftung Initiative “DESIGN FOR
Mehrweg recycling foundation.
“The creation of exclusive brands for
RECYCLING” AWARD
returnable bottles sends out a clear message IN SPAIN
about our commitment to quality and
environmental protection,” said DUH’s In Spain, a product sold in an Ecova bottle
Managing Director Jürgen Resch. “The designed by Verallia España won a “Design
emergence of modern designs for returnable for Recycling” award in 2011. Codorniu, one of
bottles provides a necessary stimulus for Spain’s leading producers of still and sparkling
returnable packaging in the water segment.” wine, was chosen because its product
design combines a proactive approach to
environmental protection with a commitment
to recycling. The Ecova Cava bottle designed
by Verallia played a key role in Codorniu’s
winning strategy.
35
verallia: a responsible employer

A SHARED COMMITMENT
The key principles of Verallia’s human resources policy are as follows:

An ongoing commitment to ensure employee health and safety

Recruitment and relations with schools and universities to further contribute

to diversity and excellence

A focus on personal growth and development in career management

Verallia places great importance on issues that
affect its personnel, such as workplace health
Access to skills and management training programs 
and safety, employee motivation, diversity,
good employee relations, labor relations,
and involvement in local communities. Employee engagement with the company’s business and social objectives

37

a responsible employer
a zero-risk culture
Verallia’s health and safety policy hinges on
the development of standards to ensure that
our sites are compliant with requirements.
We also deploy programs aimed at changing
behavior and safety management practices
among our employees, as well as temporary
staff and contractors working at our plants.
Two key performance indicators (KPIs) are
tracked at company level on a monthly basis:
the lost-time accident frequency rate (TF1)
and the non-lost-time accident frequency rate
(TF2) for Verallia personnel and contractors/
temporary staff combined.
Verallia applies specific health and safety
standards based on an analysis of the root
causes of the most frequent accidents and
their seriousness.
This process has resulted in the
development of standards for working
at heights; lock-out/tag-out of electrical
38
equipment; contractor management;
work permits for potentially hazardous
activities such as welding, grinding
and excavation; operation of forklifts;
and machine safety.
1. Focusing on the basics
Verallia has defined 4 Cardinal Rules, which
were rolled out across the company in 2009
to make employees more aware of the basic
principles of health and safety: do not bypass,
neutralize or damage any safety devices;
always wear suitable personal protective
equipment (PPE); always follow lock-out
procedures systematically; and use proper
equipment and tools at all times.
The implementation of these “4 Cardinal Rules
for saving lives” is regularly tracked in all
of the countries in which we operate.
safety
(Number of lost-time accidents + fatal accidents) x 1,000,000
all about TF1 Number of hours worked
LOCK-OUT /
Number of reported accidents x 1,000,000
TAG-OUT
Lock-out/Tag-out
TF2 Number of hours worked
is used to ensure that
electrical, mechanical Number of recorded unsafe situations x 1,000,000
Management tools Participatory tools Cultural tools
or hydraulic equipment
is de-energized before work
is carried out on it, to prevent
TF5 Number of hours worked
SMAT, monthly meetings, TF5 BBS,... the equipment from being
5S, daily safety minutes
inadvertently re-started
Comprehensive and coherent program
or re-energized by
Internal
Cardinal
rules
Safety
standards
plant-level
standards
Clear policy and
responsibilities
another person.
all about
TF1
Risk assessment for each job and task
TF2
Safety issues reported back by managers awareness of safety issues. The Porto Ferreira
2. Collaborative tools or operators from the different Verallia entities site in Brazil has launched the GOS program TF1 - Lost-time accident frequency rate
Verallia also has a number of programs as a result of activities under the SMAT and (Portuguese for Safety Observation Template), TF1 measures the number of accidents resulting in more
in place aimed at delivering progressive TF5 (day-to-day risk management) programs a series of safety discussions led by members than 24 hours of time off work. Accidents that occur
improvement in safety behavior across are followed up with associated action plans of the plant’s safety committee (operators when traveling to and from work, or to and from the
the organization. The primary aim at sites, where necessary. and employee representatives) to ensure the location where employees normally eat their meals
of the Safety Management Audit Tool (SMAT) Several sites have also embarked on a correct implementation of safety standards during the work day are not included.
program, for example, now in place at all behavior-based safety (BBS) initiative which and rules.
our sites around the world, is to enable aims to foster a safety culture among all TF2 - Non-lost-time accident frequency rate
managers and operators to discuss safety employees, particularly operators. Some TF2 measures all accidents requiring medical services
in a real work situation, in order to identify plants (for example Wirges in Germany, (fatal accidents + lost-time accidents + non-lost-time
positive behavior as well as areas for as well as Dego and Carcare in Italy) have accidents).
improvement in relation to specific tasks. provided employee training to further raise
39
 health
a responsible employer
two objectives for optimal
working conditions
We have identified two key areas of focus related to health
aspects of our industrial processes.
1. Workstation ergonomics
(movements and postures)
Health risks can relate to lifting
and handling, movements and postures,
or repetitive strain on the upper limbs.
Specialists in ergonomy support the risk
assessment process and help develop
solutions such as warm-up exercises,
awareness training and the installation
of new lifting/handling equipment.
The Lagnieu plant in France, for example,
has introduced warm-up sessions for staff
responsible for adjusting the forming
equipment at the start of a new production
40
run as part of its workplace ergonomics example, a soundproofed cabin has been
initiative. The ten-minute warm-up sessions, installed in a central location in the forming
led by two in-house instructors, take place area. The new cabin allows the operator to
before the job change process to reduce the conduct quality checks on three separate
risk of injury and back strain when handling IS machines in cooler and quieter conditions.
moulds. A number of initiatives has also been
Verallia has also produced a best introduced to reduce our employees’
practice guide for handling moulds, and the exposure to heat. In Lonigo, Italy, for
target for 2012 is to ensure that one site in example, an air cooling system has been
each country conducts a mould handling installed to boost the air renewal rate
analysis and implements the good practices and reduce the temperature for personnel
outlined in the guide. The Bad Wurzach working in the packing area.
plant in Germany has already completed
the analysis, and a number of workstation
modifications have been made to implement
the recommended practices.
2. Exposure to heat and noise
Verallia has adopted the Noise Standard
(NOS) developed by Saint-Gobain in 2004
to assess personnel exposure to noise
generated on site. A noise mapping exercise
has been conducted at each plant, and
a number of techniques have been deployed
to reduce employees’ exposure to noise
pollution. At the Pescia plant in Italy, for
41
verallia employeur responsable
a responsible employer
people: our key resource
Human resources are key to Verallia’s corporate
strategy. Our HR policy, built on experience,
wide-ranging expertise, and a commitment to the
Principles of Conduct and Action, combines the
virtues of strength and proximity by:
• Devolving management to country and
subsidiary level
• Leveraging synergies at corporate level, with
a particular focus on career management,
diversity, mobility, and the implementation of
our Principles of Conduct and Action
42
1. Recruitment and university relations
The recruitment of new employees is vital
to the ongoing development of the company.
We select candidates carefully to ensure
that they offer the right combination of
skills, teamworking ability and development
potential. New recruits’ attitude and
behavior must be in line with the Principles
of Conduct and Action, and openness to
functional or geographical mobility may
also be taken into account during the
recruitment process.
As an employer, we are committed to
diversity and equal opportunity, and our
recruitment process is designed to treat all
applicants fairly, regardless of gender, age,
ethnicity and disability.
We are also committed to increasing
the number of women we employ,
particularly in technical jobs, to achieve
a better balance between male and female
employees.
Our recruitment figures for 2011 show
that we are making progress: 32% of the
200 managers who joined Verallia last
year were women (the proportion in France
was 47%).
Verallia has an policy of active
engagement with schools and universities.
Our HR teams take part in recruitment
r ecru itme nt
events hosted by educational institutions host visits to demonstrate our industrial
to interview and select students expertise to students, and to encourage
for internships and entry-level positions. them to join Verallia upon completion
Examples include: the Forum Trium of their studies. Students from
recruitment fair, held by a group of the University of Reggio Emilia in Italy
prestigious French engineering schools; Foro recently visited our sites in Gazzo
de empleo in Burgos, Spain and a number Veronese and Villa Poma,
of career fairs in the United States. for example, while a group
To boost Verallia’s profile as an attractive from ENPC toured the Oiry
employer among universities specializing plant in France.
in our key disciplines (engineering,
packaging, sales and marketing), we also
send out speakers to talk about their career
experiences to students in specific courses.
The range of subjects and speakers is
impressive and includes a presentation on
marketing and design office activities at
the French packaging engineering school
ESIEC; an “industry jobs” seminar at the
Ecole Nationale des Ponts et Chaussées
(ENPC) engineering school near Paris, France,
attended by a Verallia plant manager; and
the design of teaching modules for Master’s
degrees at the Polytechnic University of Turin
in Italy. Plants in various countries regularly
43

a responsible employer
2. Career management and training
Our employees always have been, and always
will be, our greatest asset for growth. Their
specialized expertise, their adaptability and
capacity for innovation, and their motivation
and engagement will enable Verallia to
continue to grow and to meet new challenges
and seize opportunities.
Verallia works hard to foster a culture
of real internal mobility and development,
supported by a range of initiatives designed to
help our employees fulfill their potential.
At Verallia, we consider knowledge sharing
to be very important. Therefore, considerable
effort is devoted to training. Recent years have
seen a continuous increase in the percentage
of our workforce that has received training
(approximately 83% in 2011) and the number
of hours of training (more than 49 hours per
employee in 2011).
In 2011, the amount invested in training
by Verallia was equivalent to 3.4% of the total
payroll.
Our training programs are structured
around two principal areas:
• Skills training to develop the knowledge
44
and expertise of employees. Technical
training, for example, represented 54%
of the total volume of training in 2011
(compared with 42% in 2010). The majority
of training is provided at our in-house
training centers (such as the international
training center in Chalon-sur-Saône, France,
and the Technical Training Center in Marion,
Indiana, United States).
• Management training to develop team
leadership and project management skills
of current and future managers
In addition to conventional classroom-
based training, we also use tutoring programs
to transfer knowledge and expertise in work
situations. Tutors come from the same entities
as tutees, receive special training in tutoring
techniques, and conduct their tutoring
activities according to a structured step-by-
step program that ends with an assessment
of the skills acquired by the individual.
Tutoring programs are mainly used with
technical staff at our plants, for example
to develop skills in both forming and packing
activities (in France), or to allow operators to
be seconded for a three-week training period
car eer de velopme nt
to acquire new skills (in Spain).
We also offer training programs at our
plants for recently graduated engineers
(such as the Pépinière program in France and
the Management Leadership Development
Program in the US), whereby trainees spend
time in a variety of roles, interspersed with
specialist training sessions, over a period
of 15-30 months. Engineers are assigned
supervisory positions in operational teams
upon completion of the training program.
Mentoring programs are part of the
management development process in
Germany and the United States. Participating
managers meet with their assigned mentor—
with whom they do not have a direct
reporting relationship—on several occasions
during a period of 12-18 months. The meetings
give mentees the opportunity to discuss
issues they are facing at work, and to receive
advice and support from the mentor, often in
the form of customized action plans.
Verallia employees also have access to
a range of e-learning tools. In 2011, a series
of six technical e-learning modules about
the glassmaking process were developed by
Verallia’s training department. The modules be proactive in managing their careers.
have been translated into several languages Annual “People Reviews” are held at the
and are available to all personnel. team level in all of our countries of operation,
Finally, in each of its countries of operation, helping to identify employees with the desire
Verallia offers single-year or multi-year and potential to benefit from international
study-and-work apprenticeships for young experience. International assignments,
people (who represent approximately which last an average of three years, deliver
3% of our total workforce) in the fields of significant benefits for both the employee
production, maintenance, finance, marketing and the company: They provide
and human resources. The apprenticeships a demanding yet undeniably
combine high-quality practical experience enriching experience for the
with the theoretical training provided at employee, both personally
school, helping to make the participants more and professionally, while
employable. Some of the apprentices are promoting the development
hired as full-time Verallia employees upon of a shared culture,
completion of their course. creating synergies,
Our human resources teams and managers and fostering
have a range of tools and processes at their exchanges of best
disposal to support employees’ professional practices, all of which
development. Annual appraisal interviews, strengthen Verallia
for example, provide employees with an as a company.
opportunity to talk to their direct supervisor In 2011, 45 managers
about areas for improvement and training benefited from assignments
needs. Verallia employees also have access abroad.
to an intranet site that provides information
about internal job vacancies, allowing them to
45

a responsible employer
3. Employee engagement
employee relations
We recognize that labor union cultures
and labor relations environments vary
from country to country, and we adapt our
approach accordingly, with the same strong
commitment to ensuring constructive
and balanced dialog with employees
in all of our countries of operation.
In the United States, for example, for
the past four years Verallia North America’s
Labor Relations Director and the head
of the GMP labor union have hosted a joint
event for students at Purdue University
to promote good labor relations based
on mutual trust, communication and respect
for employees.
In France, where there is a long tradition
of social dialogue, an innovative agreement
regarding union recognition was reached
in 2011 to enable employee representatives
to reconcile their union commitments with
their professional development. Key provisions
of the agreement include support for union
officials at the beginning and end of their
46
term, training in the rights and responsibilities
of employee representatives and access
to high-level training in communication
and economics at a leading French graduate
school for labor union stakeholders.
Several other agreements have also been
signed in France in recent years, reflecting
a shared commitment to progress in areas
such as gender equality, jobs and skills
management, planning and profit sharing.
Finally, labor relations at the international
level are becoming more structured as
European labor organizations work together
more closely.
share options and profit-sharing
Verallia employees can access Saint-Gobain’s
savings plan (where local legislation permits).
Launched in France in 1988, the share option
plan has been gradually extended to include
nine countries, including some in South
America. It enables employees to build savings
over a number of years, based mainly upon
Saint-Gobain share options granted at an
attractive price.
In some countries, including France,
employee r el atio n s an d e n gageme nt
employee salaries can also be enhanced
by incentive and profit-sharing plans.
increasing employee engagement through
satisfaction surveys and family events
Employee satisfaction surveys were conducted
in Spain, Portugal, South America and Russia
in 2011 to measure employee attitudes
and expectations. Survey questionnaires
are completed anonymously by employees
and cover areas such as work atmosphere,
management, communications, pay, career
management and training. The survey results
have been reported back to all personnel,
and action plans have been implemented
to drive improvements in certain areas.
Verallia is also committed to involving
employees’ families in special events
so our personnel can share and take pride
in their everyday work environment.
Open houses held when a furnace is rebuilt,
or to mark the completion of site upgrade
projects (such as that which took place
recently at the Azuqueca plant in Spain),
provide families with an ideal opportunity
for a site visit.
47
 social au dits
a responsible employer

audits: as transparent as glass

Demonstrating its commitment to social In 2011, audits were conducted at all The audits carried out at Verallia’s sites by Intertek featured more than 400 questions relating to five main themes:
of our sites by Intertek, a firm that
and environmental responsibility and reinforcing
specializes in the assessment of companies'
its competitive advantage in these areas, performance in the fields of compliance, Wages and Management
Working conditions Health and safety Environment
Verallia was the first glass packaging company quality, safety, environment and social working hours systems
to introduce a program of audits carried out responsibility. With a network of more Child labor Working hours Work area Documentation Regulatory compliance
than 1,000 laboratories in 100 countries,
by an independent body.
and more than 30,000 employees, Intertek
is a leading provider of social and Forced labor Pay and benefits Emergency preparedness Employee engagement Effectiveness of sites’ environmental
environmental performance assessment Work-related accidents and profit sharing management systems
and certification services.
Freedom of association Equipment safety Audits and monitoring
The audit results illustrate our – –
and collective bargaining of corrective actions
employees’ commitment to sustainable
development: one-third of the 47 sites Freedom from
– Risks Integrity –
audited scored 98% or more, and two-thirds and to reduce our environmental impact discrimination
scored more than 92%. through our programs to reduce energy Chemicals and hazardous
The audits highlighted our excellent consumption, CO2 and other emissions, Disciplinary practices – – –
substances
performance in employee communications, and our structured approach to monitoring
and our efforts to stop discrimination safety performance. Work contracts – Cafeterias and break areas – –

48 49
acting locally
AUTONOMY IS EMPOWERMENT
Our company firmly believes in the potential
of glass packaging in mature economies
and emerging countries alike. Our
investments help to improve our
environmental performance, and sustain
and create jobs, allowing us to play a major
role in the socioeconomic life of local
communities.
Operating in different regions of the world
requires us to understand and comply with
50
local legislation and regulations. Equally
importantly, it requires us to respect
local practices and customs, which differ
significantly from one country to another.
Decentralized management is a logical
response that allows our facilities to benefit
from a high level of autonomy and enhances
the visibility of local operations while
benefiting from the scale and strength
of the global Verallia organization.
51

acting locally
endlessly recyclable
Glass is a fully Recyclability is a key characteristic of our
material. A bottle is recycled to become
and endlessly
another bottle with the exact same properties
recyclable packaging and qualities, resulting in a range of
material and has additional environmental benefits, such as
intrinsic virtues that lower energy consumption, reduced demand
make it a very strong
for natural raw materials and less waste
sent to the landfill. Glass is also the ideal
performer with respect candidate for deposit-and-return programs,
to the environment. where returnable bottles can be reused up to
40 times and then recycled. After use, glass
becomes a packaging waste that can be—
and is in many countries—reused as a raw
material by local communities.
The proportion of cullet used in our
furnaces is steadily increasing, with levels as
high as 95% at some of our plants.
Technically, it is possible to operate our
furnaces on cullet alone. This, however, would
depend on a high level of availability of cullet
as a resource and complete control of its
composition (recycled glass must be clean,
i.e. not contaminated with foreign objects or
52
impurities, in order to guarantee the stability
of the chemical reactions that take place
during glass melting).
Because the availability of cullet is
an essential part of our manufacturing
process, we have made recycling one of the
fundamental priorities of our environmental
policy. Most of our plants recycle all of their
glassmaking waste and, wherever possible,
accept cullet from external sources. We
have also invested in cullet treatment
centers where used glass is sorted, freed of
its impurities, and crushed to make clean
cullet that is ready to be turned into new
glass. In Italy, our Ecoglass subsidiary is the
largest company in the sector (it processes
approximately a third of the cullet derived
from glass collection) and meets most
of Verallia Italia’s cullet requirements. In
Germany, we also operate a cullet treatment
center at our Bad Wurzach plant.
In the United States and South America,
we promote the concept of glass collection
and recycling, based upon the model
already well established in Western Europe:
consumers deposit glass in collection
containers or bins; the glass is collected and
transported to treatment centers; there it is
sorted, freed of its impurities and crushed to
be made into cullet; delivered to glass plants,
the cullet is melted again to make new glass
bottles and jars; the new glass packaging
is filled at bottling plants; it is then returned
to the distribution circuit, delivered to stores
and purchased by consumers.
To raise consumer awareness about the
importance of recycling, we conduct outreach
programs both on our own and in partnership
with trade organizations (glass industry
associations).
For example, our Brazilian subsidiary
has launched a recycling project in greater
São Paulo, focusing on the collection of used
bottles from restaurants, supermarkets, bars
and shopping centers.
In the United States, Verallia created
an animated film in 2009 aimed at primary
rate school children and featuring two characters:
Captain Cullet and the Little Gob o’ Glass.
of glass This education program, now also available
recycling  on the Internet, presents the glassmaking
process by guiding children through a glass
manufacturing plant, underlining the benefits
approximately of glass and the environmental benefits
68% of recycling. Verallia North America is also
actively involved in Recycle Glass Week,
on average which the Glass Packaging Institute (GPI)
in Europe has organized each year since 2009 in the
United States. This event, which now runs for
more than 33% a month, is designed to raise public awareness
and inform consumers that recycling glass
in the bottles and jars has a positive impact on the
United States environment. GPI’s goal is to achieve 50%
recycled content in the manufacture of new
promotion of recycling
glass packaging in the United States by the
end of 2013.
As part of Recycle Glass Week in 2010,
Verallia North America and the Green Broad
Ripple Restaurant Association, a movement
to protect the environment of Broad Ripple
village in Indianapolis, organized the donation
of 100 recycling bins for glass bottles and jars
to Broad Ripple bars and restaurants.
In the Chilean capital of Santiago, Verallia
is sponsoring the installation of containers for
the recovery of post-consumer glass as a way
to promote recycling. Also in Chile, Verallia
has developed a program involving the
installation of post-consumer glass collection
points at customer sites, with separate
bins for each color (green, flint or dead-leaf
green) and condition (clean or dirty). Glass
is deposited by our customers and crushed
on-site using an easy-to-handle glass crusher.
When the bins are full, Verallia collects them.
The glass is then reinjected into the furnace
at our plant, with a target of collecting and
recycling more than 50,000 metric tons each
year. In 2012, Verallia Chile will open its own
cullet treatment center, located close to our
glass manufacturing plant.
In the United States, we have developed
a closed-loop bottle manufacturing process
in partnership with Boulevard Brewing, one
of our beer customers, which collects post-
consumer bottles and processes them for
reuse. Recognizing the environmental benefits
of glass recycling, Boulevard Brewing formed
Ripple Glass, a dedicated glass collection
and processing company, which provides
a source of cullet for our local beer bottle
manufacturing operations.
This initiative by the two companies
to promote the use of recycled glass is
accompanied by a commitment to the
principles of eco-conception, as Boulevard
Brewing is now using our ECO Series™ bottles
for part of its production.
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 our communities
acting locally

CAPTAIN CULLET: NEW WEBSITE

AND VIRTUAL PROGRAM
To promote our glass recycling education program, the Captain Cullet

community outreach
and Little Gob o’ Glass website was redesigned in 2011 and now also hosts
a virtual recycling program.
The education program is run by volunteers at Verallia North America
and GPS America, who work in the local communities where Verallia
operates. In the regions where Verallia North America is not physically
Verallia community outreach projects take a range of different forms
present, children, parents and teachers can experience the virtual program
and include financial support for various institutions, in-kind donations at www.captaincullet.com.
and employee involvement in charitable and fundraising events. The animation introduces two new characters, Professor Flint and Plant
Manager Amber, who take visitors on a guided tour using a variety
of games and puzzles. In the first part of the program, visitors are invited
to watch the two videos starring Captain Cullet and the Little Gob o’ Glass.
1. Support for economic development Agricultural production has increased The second part concludes with a quiz and a conclusion emphasizing
Conscious of the value glass adds to the and producers have diversified into such the importance of recycling. Upon completion, children can print their
products it contains, Verallia contributes to a areas as preserves, particularly tomatoes, In addition to actions directly related own personalized Glass Super Agent certificates.
number of development projects by donating for which Verallia Italia donated 20,000 jars. to glass as a material, Verallia teams pursue As well as the education program, the website features other
glass containers free of charge. In Chile, in collaboration with the Slow initiatives to help young people reintegrate 2. Actions to help seriously ill called Peace Village International, which animations and a Fun Stuff section, where children can download
In Burkina Faso, for example, Verallia Italia Food Foundation for Biodiversity, Verallia into local communities. In Brazil, or hospitalized children provides medical care and rehabilitation for an activity book, coloring pages, bookmarks, Glass Super Agent badges
took part in an agriculture and food project developed and produced a special glass for example, an employee at our Porto Many Verallia employees around the world a period of weeks or months for wounded and desktop wallpaper.
in the town of Boussouma. The project’s jar free of charge for a product called Merkén, Ferreira facility taught a group of volunteers support charitable organizations and make and sick children who cannot be treated
goal was to support economic development a traditional blend of Chilean spices. chocolate production techniques, thus financial and other practical contributions in their conflict-torn native countries. The
in the community by drawing on local The glass packaging preserves the Merkén, providing them with an additional source to help children who are sick or who have charitable foundation, based in Oberhausen, www.captaincullet.com
environmental and human resources, enhances its value and makes it easier of income. The workshop was held been injured as a result of conflicts or crises. near Essen, provides these children with the Facebook : www.facebook.com/pages/Captain-Cullet-and-The-Little-
and helping to create jobs for women as to market, contributing in turn to the in a daycare center, and the chocolates For more than 20 years, employees physical care and psychological support they Gob-O-Glass/148748345155406
a way to provide income for their families economic development of the communities were distributed to the children at the end at Verallia’s Essen facility in Germany have need until they are fit to return home. Verallia Twitter : twitter.com/CulletAndGob
and avoid displacement to other regions. that produce the product. of the session. supported an international organization Deutschland provides financial assistance and

54 55
 our communities
acting locally

3. Sponsorship of sporting events

Numerous Verallia companies offer
encouragement and support for sports teams
in their regions, particularly in the United
States, with sponsorship programs for youth
baseball, softball and basketball teams;
and in the Ukraine, with sponsorship for an
international junior tennis tournament and
a girls’ swimming team.

4. Support for education and training

in-kind donations and also takes part
in events organized by the foundation.
To mark the 50th anniversary of Blédina’s
“petit pot” line of baby foods, Verallia France
lent its support to an operation called
“Une photo, un rire d’enfant” organized
by Le Rire Médecin, a charity that sends
clowns to pediatric wards in hospitals.
The operation, which ran from May 9 to
October 31, 2011, invited the public to post
funny photos on a dedicated Facebook page.
Blédina supported Le Rire Médecin
and committed to funding up to 5,000 clown
visits to hospitals. Verallia France publicized
the operation on its corporate website.
Verallia North America provides financial
assistance for hospitals caring for children
with leukemia, while employees at Verallia’s
plant in Kamyshin, Russia donated medical
equipment to a local pediatric hospital.
Lastly, employees at the Água Branca
facility in São Paulo, Brazil, have formed a
volunteer group called “Join Us” to create
a sense of team spirit around charitable
initiatives, such as organizing parties at
orphanages, and visiting and giving gifts to
children and teenagers with AIDS at local
specialist centers.
Numerous projects to support education and
training have been launched at Verallia sites
around the world.
For example, Verallia Argentina has
partnered with universities to provide
financial resources and training in technical
subject areas, while promoting Verallia as a
potential employer.
In São Paulo, Brazil, Verallia supports a
project called “Menores Aprendizes” (junior
apprentices), which organizes training
programs and internships for young people
aged 15 to 18 to help them find employment
and better integrate into society.
Publisher: Claire Moses
Editor in Chief: Gina Behrman
Editorial: Kristel Liarçou
Translation: eFiles
Photos: Saint-Gobain Emballage, Bernard
Gouédard, Saint-Gobain Vetri, Aline le
Normand (École Boulle), Clémence Couchot
(École Boulle), Arnaud Bouissou, Burwell
Photography, Glass Packaging Institute,
Gerolsteiner, DCM Associati
Illustrations: Pascale Testanière
Design & layout: www.ad-nova.com
©Paris 2012, Saint-Gobain Emballage
All rights reserved
No part of this publication may be reproduced

56
 Verallia
18, avenue d’Alsace
Les Miroirs - 92096 La Défense Cedex
Tel. +33(0)1 47 62 38 00
Fax +33(0)1 47 62 39 55

www.verallia.com the many lives of glass