A Life Cycle Engineering model for technology selection: a case study on plastic injection moulds for low production volumes

The selection of the most appropriated technological solution to produce a certain mould able to competitively produce parts in polymeric materials is a multi-disciplinary activity, which integrates different knowledge fields and professional domains. The selection decision should capture not only the technical performance required for the mould to produce the final part in the expected quantities and intended quality, but also the economic issues and environmental impacts originated all along the mould life cycle. In this paper a Life Cycle Engineering (LCE) model is proposed to support the selection of alternative technological solutions through the integration of these three analysis dimensions underlined by the LCE approach. The model proposed has the novelty of integrating the three dimensions through the use of easy-to-read ternary diagrams allowing the identification of the “best domains” of each technological alternative. With the integrated analysis, the present model fosters the global comparison of alternatives according to different business scenarios and corporate strategies, supporting an informed decision-making process. The model was applied to a case study aiming the production of very small production volumes of polymeric parts. Two candidate technologies were evaluated: one involving a mould made of a spray metal shell backfilled with resin and aluminium powder and another based on the machining of aluminium.     

The energy consumption and environmental impacts of a color TV set in China

The present study analyses the different processes followed during color TV set production along with the energy consumption and the environment emissions in each stage. The purpose is to identify “hot-spots”, i.e. parts of the life cycle important to the total environmental impact. The analysis is performed using life cycle assessment (LCA) methodology, which is a method used to identify and quantify in the environmental performance of a process or a product from “cradle to grave”. LCA methodology provides a quantitative basis for assessing potential improvements in the environmental performance of a system throughout the life cycle. The system investigated includes the production of manufacturing materials, transport of manufacturing materials, color TV set manufacturing, transport of color TV sets, use of color TV sets, discarding color TV sets and partial plastic waste energy utilization. The environmental burdens that arise from color TV sets are mainly due to air emissions derived from fossil fuel utilization.     

A mathematical programming tool for LCI-based product design and case study for a carpet product

Products are produced by a series of energy-intensive transformations of raw materials such as crude oil. The life cycle inventory (LCI) of mass and energy usage in these supply chains is one measure of overall environmental performance. In this paper, we present a methodology to examine the life cycle choices available for a product and optimize these choices based on criteria derived from mass and energy efficiency. A two-phase framework for production path construction followed by optimal path selection was developed. This framework can be applied to improve the overall LCI energy characteristic of a product when there are different production and recycling options for different product constituents. The scope of the life cycle is from raw material extraction through the production system and does not include the use and disposal phases. The approach is illustrated in a case study of the EcoWorx™ carpet system of Shaw Industries, which includes the inclusion of several recycled material options.     

Measurement of green productivity and its improvement

The measurement framework of the green productivity (GP) of a product system, or process, and its improvement are discussed. Two types of GP indicators are developed to help understand the practical concept and executive approaches of GP, using environmental management tools such as life cycle assessment (LCA) and total cost assessment (TCA). GP index is defined as the ratio of productivity of a system to its environmental impacts. This index is intended for estimating the GP performance of an existing product or process and comparing it with other equivalents. Specifically, the GP index is a measure of the GP performance of a product system throughout its entire life cycle. The “overall” GP index can be divided into a “direct” GP index and an “indirect” GP index which are intended to analyze the GP performances of direct production processes and indirect upstream processes, respectively. For internal managerial decision, GP ratio is developed to select one alternative out of a list of contenders in order to improve the GP performance of an existing system. In addition, GP portfolio is drawn up to check the strengths and weaknesses of alternatives. A case study of a petrochemical company in Korea is provided as an example for illustrating the feasibility of the indicators developed here (GP index and GP ratio) for the measurement of GP and its improvement.     

Results of the first adapted design for sustainability project in a South Pacific small island developing state: Fiji

With high population densities concentrated in predominately coastal zones, the South Pacific will, in this century, be heavily impacted by global temperature and sea level rises. Small island developing states do have a number of unique problems, namely, small scale economic development together with environmental sustainability. This paper presents the lessons learnt from the implementation of the first cleaner production and design initiative project conducted in a Pacific small island developing state(s) (SIDS) using the design for sustainability (D4S) methodology. The final product was analysed using the life cycle assessment (LCA) method. Implemented within a medium-sized enterprise operating in Fiji, the Cook Islands, and Samoa, the project focused on improving an existing product and its associated life cycle to make it more environmentally friendly to manufacture, retail, and dispose of. The project outcomes revealed that D4S provides a suitable tool for a country like Fiji to pursue more intensively an eco-friendly manufacturing agenda. However, when combined with LCA, the qualitative nature of D4S shows that not all solutions produce the best overall result. Specifically, the “improved” design, whilst being less impactful on Fiji in terms of disposal, has a higher impact globally due to the production and manufacture of the new materials used. For this reason designers need to address the impact criteria and decide whether a domestic or international agenda is of greater concern within the SIDS context.     

Emergy as a tool for Ecodesign: evaluating materials selection for beverage packages in Brazil

The life of a product begins with the initial product design concepts; the costs and potential impacts of a product are heavily influenced by the final design, the production processes, the economic and environmental costs of all raw materials. Additionally, both of these factors are very much affected by how the products are managed during and after consumer usage. Thus, there is an urgent need for a tool to facilitate the integration and assessment of environmental and economic demands into the product planning and development processes. The introduction of environmental accounting based on emergy as a tool to assist in product design is proposed. This complementary tool may be inserted into the conventional design methodology to facilitate in the selection of materials and processes as well as in the actual design of the products. To illustrate the application of the proposed method for material selection, PET (polyethylene terephthalate) bottles and aluminum cans for beverage packaging are compared. Despite the exceptional condition of aluminum recycling in Brazil, results show that the best option for beverage packages is the PET bottles.     

Development of environmental performance indicators for textile process and product

The increasing demand for environmental performance evaluation of industry requires development of sector-specific environmental performance indicators (EPIs). For the consumer product manufacturing industry, in this case the textile industry, the need to evaluate environmental performance both from process and product life cycle perspectives leads to development of EPIs of process and product dimensions. Such types of EPIs have been developed, with best achievable values being identified, by this study for cotton woven products and wet processing. An in-depth discussion has been presented concerning problems in developing and applying EPIs, while areas for further research are also recommended.     

Manufacturing actor’s LCA

Modern industrial environmental management encompasses life-cycle thinking. This entails considering not only the emissions and resource use of the company’s production processes, but also the environmental consequences of all processes related to a product’s life cycle. However, no single actor can influence the whole life cycle of a product. To be effective, analysis methods intended to support improvement actions should therefore also consider the decision makers’ power to influence.Regarding the life cycle of a product, there are at least as many perspectives on life-cycle thinking as there are actors. This paper presents an approach with which manufacturing decision makers can sharpen the focus in life-cycle assessment (LCA) from a conventional ‘products or services’ emphasis to a company’s manufacturing processes. The method has been developed by combining knowledge gained from earlier LCA studies with new empirical findings from an LCA study of an SKF manufacturing line.We demonstrate how system boundaries and functional units in an LCA can be defined when adding the perspective of a manufacturing decision maker to the product life-cycle perspective. Such analysis helps manufacturing decision makers identify improvement potentials in their spheres of influence, by focusing on the environmental consequences of energy and material losses in manufacturing rather than merely accounting for the contributions of individual stages of the life cycle to the overall environmental impact. The method identifies and directly relates the environmental consequences of emissions or raw material inputs in the product life cycle to manufacturing processes. In doing so, the holistic systems perspective in LCA is somewhat diminished in favor of the relevance of results to manufacturing decision makers.     

Life cycle assessment of a domestic cooker hood

A life cycle assessment (LCA) of a domestic cooker hood was conducted. Cradle-to-grave analysis was performed using the GaBi software with Eco-Indicator 99 (Egalitarian Approach). The most polluting phases were “manufacturing” and “use”, the environmental impact being affected especially by production materials and the electricity consumed during the product’s lifespan. The study also highlighted that the hood’s environmental impact is closely related to the local power grid mix. This aspect was further analyzed by entering the data for operating it both in Italy and in France. Finally, the improvements obtained by replacing the single-phase electrical motor with an inverter-driven three-phase induction one and the halogen lamps with Light Emitting Diode (LED) lamps were assessed with the LCA. These changes entail an improvement of the environmental impact of 36% in Italy and of 24% in France.     

Development and environmental improvements of plastics for hydrophilic catheters in medical care: an environmental evaluation

Single-use medical devices have been under close scrutiny for several years, especially the choice of plastic materials. Many different requirements such as medical safety, treatment functionality and efficiency, environmental performance, etc. have to be fulfilled. Today, the most commonly used materials for hydrophilic urinary catheters are polyvinylchloride (PVC) and thermoplastic polyurethane (TPU). In this research study, these two materials' environmental performance was evaluated. In light of the knowledge gained in that study a new plastic material for use in urinary catheters was developed. The aim of the development of this new material was to design a high performance material with superior environmental performance. The newly developed plastic material is a polyolefin-based elastomer. The ecological environmental performance of the new material was evaluated and compared to the existing plastic materials. The study focused exclusively on the choice of plastic materials and their ecological environmental performance.The analysis has been performed using a system perspective and a life cycle assessment (LCA) methodology. The functional unit has been set to the treatment of one patient during one year. The results from the LCA models have been presented both in terms of direct inventory data, such as energy use and formed emissions, and in terms of the results from four different impact assessment methods. Analysis of the results based on direct inventory data, i.e. common inventory results such as energy resource uses and emissions of CO₂, NO_x and SO₂ show an overall better environmental performance for the new polyolefin-based elastomer compared to the existing PVC and TPU plastic materials. The normalization and weighting steps in the analyzes have indicated the importance of energy resource uses and global warming as indicator for the environmental performance even if other impact categories also can play a role. In the environmental impact assessment, the polyolefin-based elastomer showed a clearly better environmental performance than the TPU material. Compared to PVC plastic material the new polyolefin-based elastomer showed an almost equivalent environmental performance. This can be mainly explained by the different materials' energy use. The new material has thus also shown to be an environmentally good alternative to PVC if a PVC-free material is requested. Basing the plastic formula, on simple bulk plastics with low energy use in the production of single-use medical devices, has been shown to be a successful method of producing high quality products with superior environmental performance.     

The recycling of plastic wastes from discarded TV sets: comparing energy recovery with mechanical recycling in the context of life cycle assessment

Two treatment options, i.e. energy recovery and mechanical recycling of plastic wastes from discarded TV sets, were compared in the context of life cycle assessment (LCA) methodology. An estimate for the environmental burden of each option was calculated as the sum of the depletion of abiotic resources (ADP), the global warming potential (GWP), the acidification potential (AP), the photo-oxidant formation potential (POCP), the eutrophication potential (EP), and the human toxicity potential (HTP). After calculating the environmental burden of each treatment option, a sensitivity analysis was conducted. The ultimate aim was to indicate which parameters of the system have the strongest influence on the results of the LCA in order to find ways for lowering the environmental burden, and ultimately suggest a “design strategy” for TV sets.The main finding of this study was that mechanical recycling of plastics is more attractive treatment option in environmental terms than incineration for energy recovery, which generates a larger environmental burden. Finally, based on the results of sensitivity analysis, a “design strategy” was suggested, i.e. reducing the number of plastic types being used in the manufacturing process of TVs – preferably excluding the PVC.     

Collaborative activity with business partners for improvement of product environmental performance using LCA

Collaborative activities with business partners have potential to improve environmental performance of product and life cycle assessment (LCA) is an essential technique to implement eco-design of product and production process. However, collection of LCA data from supply chain is a major issue for LCA practitioners. We propose a Supply Chain Collaboration Model (SCCM), which is a framework for collecting producer-specific LCA data from business partners and for promoting improvement activity of product environmental performance. We demonstrate the practicability of the SCCM using three case studies. In each case study, two or three partner companies organized a product improvement project and carried out process analysis techniques such as LCA and material flow cost accounting (MFCA). As a result, improvement activities from the economical standpoint could provide an incentive for business partners to collect LCA data, and thus the SCCM is an effective framework for eco-design.     

Significance of intermediate production processes in life cycle assessment of electronic products assessed using a generic compact model

In this paper a generic model for life cycle inventory (LCI) data collection is presented and applied to a product system of a Digital System Telephone (DST). It is shown that the intermediate unit processes (IUPs) are of global warming importance. Compared to earlier efforts in the field of environmental life cycle assessment of electronic products, this model enables a more partitioned LCA result, with respect to both components and processes. In our model the components are first divided into main groups and then into sub-groups. This division results in process modules for unit processes, some of which are similar to the ongoing components, thus, reducing the computational effort. The model is demonstrated for a “cradle-to-gate” calculation focusing on greenhouse gas emissions. Using scenario analysis for integrated circuits and printed wiring boards, the possible contribution from IUPs was analysed.     

Life cycle inventory data for materials grouped according to environmental and material properties

Environmental data are presented for material groups to be used in simplified life cycle assessments at an early stage in product design. Life cycle inventory (LCI) data from cradle to gate were evaluated for 214 material cases used in mechanical design. Based on their environmental and physical properties, materials were structured into 17 different groups. The environmental characteristics of each material group were expressed in terms of LCI data as well as characterised and weighted inventory data. LCI data categories contributing significantly to environmental impact were identified. Multivariate analysis showed weak correlation between material properties and environmental impact. The environmental data presented provide averages of LCI data for each material group and can be used as estimates when LCI data for specific materials are missing.     

工程材料LCA中环境效益的分析与研究

论述了材料环境效益性的目标因素,详细分析产品材料在LCA中的环境效应性、能量消耗性和经济回收性;通过LCI分析建立环境效应、能量度量、经济度量的决策模型和数学模型实现材料环境效益性的目标;先整体定性分析LCA工艺,再定量计算环境效益的三属性值,建立目标函数、分层优化算法确定影响因子和相应的权重系数之间的关系以及对产品材料的环境效益性的影响,最后以家用小型风扇回收处理中各种材料环境效益性为例进行具体分析和决策,进一步明确和决策优化出环境效益性好的工程材料。     

Assessment of the ecodesign improvement options using the global warming and economic performance indicators

In this paper, an assessment method is proposed for ecodesign improvement options using global warming and economic performance indicators. A reduction in the GHG emissions in the entire life cycle stages of a product was chosen as the global warming performance of the product. The external cost which converts the external effect of global warming into a monetary value was chosen as the global warming performance indicator in order to measure the performance of the GHG reduction of the product. The life cycle cost (LCC) of the product was chosen as the economic performance indicator to measure the performance of the life cycle cost reduction of the product. The assessment method based on the two performance indicators was applied to the liquid crystal display (LCD) panel for a case study.     

Simulating operational alternatives for future cement production

To support decisions on product and process development options and strategic planning, information on the consequences of planned changes are needed. For this purpose a flexible model for cement manufacturing has been developed. The model predicts the environmental, product and economic performance in a life cycle perspective, simulating different operational alternatives. Interesting future operational alternatives, such as an increase in the use of industrial by-products and wastes as raw materials and fuels have been explored. The results, i.e. the consequences from a life cycle perspective of potential development options, are discussed.The nine simulations show that the use of recovered material and alternative fuel (defined waste) can be increased while maintaining the current requirements on clinker performance. An increase in the use of recovered material and alternative fuel replaces the use of resources. The simulations also show that the emissions of CO₂, NO_X, SO₂, CO, VOC, CH₄ and dust can be reduced between 30 and 80% depending on the use of recovered material and alternative fuel. The transport of recovered material and alternative fuel increases with increased use. However, the environmental benefits of the increase in use of recovered material and alternative fuel are by far greater than the resource use and emissions to air associated with the increase in transport.     

Resource consumption and emissions from olive oil production: a life cycle inventory case study in Cyprus

“Cradle to gate” life cycle analysis (LCA) has been used to evaluate the consumption of raw materials and emissions of pollutants from olive oil production in Lythrodontas region in Cyprus, in order to identify the processes which give rise to the most significant environmental burdens. The system investigated includes the production of the chemical inputs used (fertilisers and pesticides), agricultural processes, the industrial processing and the transportation and waste management associated with olive oil production. Raw material and energy use as well as emissions were quantified on the basis of a functional unit of 1 l of extra virgin olive oil. The production of the inorganic fertilisers used in the agricultural stage of olive oil production and the disposal of liquid effluent from olive mills to evaporation ponds were found to be “hot-spot” processes not only in terms of resource consumption but also in terms of emissions into the environment.     

Application of a comparative multidimensional life cycle analysis in solid waste management policy: the case of soft drink containers

The paper describes the application of a multidimensional life cycle analysis (LCA) for packaging soft drinks in Israel. The suggested approach combines the conventional product LCA, vertical summation of all environmental burdens along the chain of production, use and disposal activities, and horizontal comparison of different products and disposal options, such as recycling, incineration or landfilling. The paper attempts to show that the most effective, as well as transparent, means of comparing packaging alternatives, is to place them on a commensurate basis, the most appropriate one being a monetary basis. Taking into account limitations and drawbacks of monetary valuation of non-market assets (namely, environmental assets), the study derived estimates of environmental benefits and damages associated with each alternative. The production of soft drinks containers in Israel, used here as an example for the above mentioned considerations, is based mainly on imported materials, since natural resources such as oil or bauxite do not exist in Israel. Locally, only direct production and pollution abatement costs are incorporated in the final bill, while global environmental burdens are excluded. Countries extracting and producing raw material for the packaging industry, in effect, grant an environmental subsidy to the final users, in this case — the Israeli user. The paper suggests that only by globalization of externalities and fully internalizing environmental costs into the price of the final product (the packaging material or the packaged product), an equitable full environmental accounting can be designed. This mechanism can be even accompanied by global trading in the relevant environmental credits. Decisions will, consequently, follow a sustainable path, in both importing and exporting countries.     

Environmental management accounting as a reflexive modernization strategy in cleaner production

Understanding the material purchase value of wastes and emissions and related processing costs is the essential contribution of an Environmental Management Accounting methodology proposed by a United Nations expert working group organised through the Division for Sustainable Development (UNDSD). Tracing costs and benefits according to this UNDSD methodology, considered as a “reflexive” modernization strategy in this article, sheds new light on cleaner production initiatives for corporate sustainability. Information on the first category of costs, waste and emission treatment, is generally the most accurate. Information on the second category, prevention and environmental management costs, is more difficult to determine because this category overlaps with, or is confused with, the first category of costs. Data for the two novel and innovative cost categories of the material purchase value of waste and emissions and related processing costs are even harder to obtain. Frequently, the costs are either hidden in overhead accounts or are not recorded because they are not required in conventional accounting systems. The outcome is that companies, even though they may profess otherwise, have very little knowledge about their full environmental costs, cost saving opportunities, or how best to achieve cleaner production initiatives to promote corporate sustainability. A more systematic application of the UNDSD EMA methodology would provide a better record of costs and act as a catalyst in promoting cleaner production processes. This application inevitably requires “reflexive institutions” including “reflexive corporations”, that is, corporations with the capacity to examine the side effects of their operations as modernization rebounds upon them.