Managing the environmental performance of production plants

Almost all of the Group’s tire plants, latex processing units, main Technology Center facilities and headquarters offices in Clermont-Ferrand have been certified to ISO 14001 standards. The only exception is the Tigar plant in Serbia, which was acquired in 2006 and will be certified in 2010. To manage the environmental performance of its production plants, Michelin has developed a propriety standard, the Michelin Environmental Management System (MEMS), which has been deployed in 98% of R&D facilities, production facilities and plantations acquired more than five years ago and is now being introduced in the logistics centers. Today, risk prevention practices are being integrated into the MEMS to upgrade it to an Environmental and Risk Prevention Management System (SMEP).

By the end of 2009, the new system had been deployed in more than 70% of production facilities, with full roll-out scheduled for completion in 2011. In addition, issues related to the environment, health, workplace safety and industrial risk prevention are addressed by an Environment and Prevention network comprised of around 100 experts and by a dedicated team at each plant.

Ambitious goals

A special indicator – the Michelin sites Environmental Footprint (MEF) – is now included in the Group’s management indicators, with data reported quarterly. The goal is to reduce the MEF by 30% in 2013 compared with 2005. In 2009, despite the significant reduction in production volumes, the MEF remained stable at 78.1.

Despite the recession, progress is continuing to be made in the total weight of waste produced, the total weight of waste landfilled and the quantity of CO₂ emissions. However, the reduction in output in 2009 had the effect of masking these gains, which are expressed per tonne of tires produced.

Energy efficiency and renewable energies

By the end of 2009, energy audits had been conducted and action plans prepared at more than 84 sites. Many of these facilities are already in the follow-up audit phase, and all of them will have been audited by the end of 2010. Following diagnostic reviews performed in 2008, the production plants are continuing to deploy renewable energy projects, aligned with the local environment. Other large-scale projects will extend existing installations, which have already reduced CO₂ emissions by 30,000 tonnes in 2008 and 23,000 tonnes in 2009.

Two wind turbine units are scheduled to come on stream in Northern Ireland in 2010, while a biomass-fired steam generation system is currently being implemented at two plants in France. New solar roof panels that will generate nearly two megawatts of additional electricity will be installed on facilities in France and Germany next year. Indeed, Michelin is a leader in solar energy, with 11 megawatts already generated by nearly 300,000 square meters of photovoltaic roof panels on its plants in Europe.

Reducing VOC emissions and waste

The introduction of solvent-free manufacturing processes and strict emissions management systems drove a further 2.9% year-on-year reduction in emissions of volatile organic compounds (VOC) per tonne of tires produced in 2009, representing 2,000 tonnes of VOC that were not released into the atmosphere. A quality system focused on “getting it right the first time” has reduced the reject rate through more effective management of manufacturing processes. In addition, every production facility has set targets to reduce process waste, while rubber, textile and metal fabric and metal scrap is reinjected into the production process whenever possible. In a commitment to totally eliminating landfilled waste by 2013, Michelin actively supports the development of sustainable resource recovery channels for scrap unsuitable for reuse in its production processes and other industrial waste.

Reducing water consumption

Michelin plants use water for cooling and heat transfer systems. To limit water withdrawals, open cooling circuits are gradually being replaced by closed loop systems while consumption is carefully tracked to prevent the risk of leaks and waste.

Examples of plants that have successfully reduced water consumption (based on 2008 data compared with 2005) include:

• Fort Wayne, Indiana: water consumption reduced 40% by installing closed loop cooling systems, eliminating leaks in the fire protection system, and improving processing quality (fewer purges).

• Alessandria, Italy: water consumption reduced 24% by optimizing the reuse of boiler water.

• Victoria, Romania: water consumption reduced 19% by reducing leaks in water and steam pipes.

Protecting biodiversity and ecosystems

In addition to the initiatives in Bahia, Brazil, a number of programs have been undertaken to study and protect biodiversity on Michelin sites.

• The plant in Nyiregyhaza, Hungary conducted a pilot Ecosystems Services Review(1) to assess the impact of its production operations on the local ecosystem. Another assessment method will be tested in 2010.

• In southern Spain, the Almeria Experimentation Center (CEMA) covers some 4,500 hectares, of which 1,500 are located within the Cabo de Gata Nijar Natural Park. This arid volcanic region is home to a number of species that are very rare and sometimes unique. Certified ISO 14001, the Center is harmoniously integrated into its surroundings, which it has helped to protect from erosion by planting more than 30,000 trees and bushes.

• In France, wetlands near the Cholet plant have been rehabilitated by highly committed employees. An artificial pond has attracted a wide variety of species, while a partnership with the local tourist office is welcoming visitors to the site and raising their awareness of these highly diverse yet vulnerable areas.

• In the United States, Michelin is participating in the Wildlife And Industry Together program (WAIT), which encourages businesses to protect wildlife habitats on their land. The Laurens Test Center, the Greenville research center and the Lexington, Sandy Springs and Starr plants have all been WAIT-certified.

• In 2010, a new method for assessing our plants’ impact on ecosystems will be deployed with an independent outside organization.

Logistics: a new area for improvement

The Group’s CO₂ emissions resulting from the maritime transport of goods and finished products totaled 185,000 tonnes in 2008, as measured using coefficients defined by the Clean Cargo Group. Annual CO₂ emissions from the transport of semi-finished products and tires in Europe have been estimated at 295,000 tonnes a year. This initial estimate will enable the deployment of action plans to curb these emissions.

As a member of the Alliance for European Logistics, Michelin actively promotes the European Modular System concept. The Group organizes overland transport to reduce empty truck mileage, optimizes the location of logistics facilities to improve utilization rates, and trains transport providers in eco-driving practices and proper tire use. In the United States, Michelin is participating in the Environmental Protection Agency’s SmartWay Transport Partnership. Today, more than 50% of its freight is handled by SmartWay-certified trucking companies, which have committed to improve their environmental performance by optimizing truck routes and equipping fleets with automatic tire pressure control systems or low rolling resistance tires. Michelin is also improving its load planning and optimizing truck loads.

Categories: Energy - Sustainable mobility

Keywords: CO2 - -