GREEN MANUFACTURING

Presented by: Submitted

to:
Shashank Tripathi Dr. G Venkatesh

193520 (MED) NIT Warangal.

Contents

 Introduction
 Origin
 Transformation to green manufacturing.
 Industrial perspective.
 Technologies for green manufacturing.
 Framework for successful implementation.
 Real world examples.
What is Green Manufacturing?

 Started in early 1990’s.

 “Green” in green manufacturing stands for ecological

sustainability and encompasses many different concerns
including, but not limited to, air, water and land
pollution, energy usage and efficiency, and waste
generation and recycling.

 Basically any process or activity that helps the

environment can be termed as green.
 Why Green Manufacturing?

1) Rising emissions and associated climate change

 At the current rate, emissions will double by 2050. This will

lead to a corresponding temperature rise of 4–6°C.

 This unprecedented change is expected to have a grave impact

on the global ecosystem, hydrological system, sea level and
crop production and related activities.
• Emissions are expected to grow exponentially if no
immediate action is taken.
 2) Fast depletion of natural resources

 With ever increasing population and industrialization,

the consumption of natural resources is rapidly on the rise,
while their availability is shrinking.

 Leading to periodic mismatches in demand–supply and

highly fluctuating prices, impacting both corporate
margins and consumer spend.

 There is an urgent need to

(a)adequately manage the use of these resources.
(b) find and develop alternatives
which are less scarce (renewable).
3) Growing waste generation and pollution

 Increased industrialization and urbanization have led to

significant growth in waste generation and
environmental pollution.

 Industrial waste with chemical composition can be

potentially dangerous to health, and its disposal without
treatment is leading to land and water pollution.

 As the demand and use of electronic products rise, e–

waste is also becoming a major source of environmental
pollution.
Transformation to green manufacturing.

3 key areas

Green Green Green

Energy products operations
1. Green Energy

 Green energy involves production and use of

cleaner energy.

 This is the first and most obvious step given the

dependence of industry on energy.

 Green energy includes both deploying renewable

energy sources like CNG, wind, solar and biomass
and achieving higher energy efficiency in
operations.
2. Green products

 Developing greener products is the second step in this

transformation.

 ‘Recycled’, ‘Low carbon footprint’, ‘Organic’ and

‘Natural’ are becoming popular buzz–words which are
associated with Green products.

 Developing Green products can often mean higher costs.

 However, by developing Green products that are sought by

consumers, and effectively marketing them, companies
can derive additional volumes and price premiums,
which can offset their cost of development.
3. Green operations
 The third area is implementing Green processes in
operations.

 This entails efficient use of key resources.

 Reducing waste generation through lean operations.

 Bringing down the carbon foot–print and conserving

water.

 Employing Green processes improves operational

efficiency and lowers costs.
Industrial perspective.

 Green as an Integral Part of Business

 A survey revealed that 92 percent of the companies are already engaging
in Green initiatives in some way.
 Improved company image was the most important reason for adopting
Green, followed by cost savings, maintaining competitive advantage and
increasing employee morale.
 The survey also revealed that different industries have significant
differences in the way they are impacted by Green issues, although
some issues are common to all.

 For example, increasing consumer concerns for sustainability and the

depletion of natural resources such as oil, are the top issues for the
automotive industry.

 In comparison, water shortage, population growth and environment

pollution are the top concerns for the agriculture and water related
industries.

 This means that manufacturing companies have to first understand the

key drivers of concerns in their respective industries, and then develop
specific Green strategies to address them.

 The more innovative companies have seized this as an opportunity to

differentiate themselves from their peers and enhance their competitive
advantage.
Standard setting for companies
Green in Traditional Industries
3 major industries.

Power generation

Transportation

Manufacturing
These 3 industry constitute of more than 80% of CO2 emissions.
Power Generation

 The world will consume 28000terawatt-hours of energy by 2020.

 65% to 70% of this energy still comes from coal, oil and gas.
 The first challenge is that of increasing global warming with GHG emission
levels already exceeding 380 parts per million (ppm) and projected to reach
400–430 ppm by 2020.
 Second, with scarcity of fossil sources ever–increasing, energy prices are
expected to rise, especially as economies around the world emerge from the
economic crisis.
 The power generation industry will have to reinvent itself over the next few
decades to address these challenges and shed the tag of the largest emitter
of GHG.
 Many Green energy technologies are now available to them. Some of them are
becoming competitive with fossil fuels while others are still expensive.
 As the economies of scale take effect in the future, the cost of these
technologies is expected to fall and the share of clean alternatives in power
generation is expected to rapidly increase across regions.
 Transportation

 The second most ‘non–Green’ industry is transportation.

 Increasingly stringent Government regulations, higher oil prices,

and aided by the enhanced public approval of Green brands,
leading automobile manufacturers to explore ways to reduce the
CO2 emissions of their vehicles and increase fuel efficiency.

 The automotive industry is investing heavily in the development

of new clean propulsion technologies.

 These include hybrid vehicles and power trains, fuel cells, and
electric cars.
 Manufacturing

 Lets consider example of steel industry.

 Steel is an energy–and–emissions–intensive industry, relying
heavily on fossil fuels.
 For many steelmakers, adopting Green is no longer merely an
option, but an imperative.
 Regulators are tightening controls and raising fines on GHG
emissions and waste disposal.
 Meanwhile, investors prefer companies that are managed
for environmental sustainability.
 Energy cost accounts for a large share of the cost of
production of steel — more than one–third for an integrated
steel plant.
Technologies for Green Manufacturing
1) Carbon sinks
A carbon sink is a natural or artificial reservoir that accumulates and
stores some carbon-containing chemical compound for an indefinite
period.
Two types of carbon sinks

Natural Artificial
(Plants, soil, ocean bed) Carbon Capture and Storage (CCS)
CCS developed for use in power plants that are fired by fossil fuels
such as coal.
2) Efficient fuels
This category encompasses a class of technologies that use cleaner fuels
for generating power.

Examples include biomass, hydro power, Integrated Gas Combined Cycle

(IGCC), etc.

3) Consumer Green
More consumer products that are made from sustainable process or
materials, recycled material such as (waste plastics, scrap metal, paper
etc.)

4) Green transportation
Electric vehicles, fuel cells, and bio–diesel are some examples of this
category. Not only for mobility but also for transportation of goods.

5) Industry efficiency
This category refers to the use of Green production methods and
technologies in traditional industries.
Use of efficient machines, effective usage of resources.
Implementation Framework

• Implementation of a green framework is a three step process:

Plan

Execute

Communicate
Real world examples:

ADIDAS
 Recently, Adidas signed the Climate Protection Charter for
the Fashion Industry at the UN Climate Change Conference in
Katowice, Poland, and agreed to reduce greenhouse gas
emissions by 30 percent by 2030.

 In addition, Adidas is committed to using only recycled

polyester in every product and on every application where a
solution exists by 2024.

 Founding member of the Better Cotton Initiative, Adidas

meanwhile sources only sustainably produced cotton.

 Since 2016, Adidas stores no longer use plastic bags.

 BMW
 Recently, BMW announced a $12 million investment to add two new,
highly efficient gas turbine generators capable of producing
11,000 kilowatts (kW) of electricity.

 The new turbines have the capability to increase electrical output

from 14 percent up to almost 30 percent of the plant’s current
electrical demand.

 The Landfill Gas project will return an additional average annual

cost savings to BMW of up to $2 million and reduce carbon dioxide
emissions by approximately 92,000 tons per year or the
equivalent to the benefit of planting over 23,000 acres of trees
annually.

 In addition, BMW Manufacturing recycles over 83 percent of all

waste streams and uses Solar energy to power the a trash
compactor in the company’s main cafeteria.
APPLE

 Standard recycled aluminum accumulates impurities each time

it’s recycled.

 Apple re-engineered a way to use only recycled Aluminum for

there production. This material can be recycled again and again.

 Using recycled tin in devices will prevent Apple from mining

almost 29,000 metric tons of tin ore in 2019.

 More than 40 components in iPhone XS, iPhone XS Max and

iPhone XR contain recycled plastic

 100 per cent of the wood fibre in Apple’s packaging comes

from recycled sources or responsibly managed forests.
 BPCL
 Mechanized oil recovery system for oil recovery from oily sludge to
recover the oil from the crude tank bottom sludge.

 The remaining soil having low oil content is bio-remediated with the
help of specialized micro-organisms based “oil zapper” technology.

 A Bio Gas plant has been installed at Mumbai refinery to convert

canteen food waste into gas for use in canteen.

 Re-circulating sea cooling tower systems instead of once through sea

cooling water system thereby minimizing the sea cooling requirement
and effluent discharge to the sea.

 Improvement in Energy Efficiency of the Refinery by installing highly

efficient boilers and heat recovery systems.

 Use of high emissivity ceramic coating on furnace refractory &

radiant tubes to improve furnace efficiency & save fuel.
Larsen & Toubro
 Generating power through renewable sources, such as solar and wind.
 Recycling construction materials to reduce pressure on the Earth.
 Harvesting rainwater and treating wastewater to reuse in
manufacturing processes.
 Involving employees in maintaining the quality of local air and water.
 Fitting daylight control and occupancy sensors in buildings to reduce
electricity usage.
THANK YOU