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7/27/2019 Environ Leoni
1/24
The Quality Connection
Environmental reportWire & Cable Solutions Division
2007 to 2010
7/27/2019 Environ Leoni
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CERTIFICATE The Certification Body
of TV SD Management Service GmbH
certifies that
LEONI Kabel Holding GmbHStieberstrae 5D-91154 Roth
including the sites and scope of applicationsee enclosure
has established and appliesan Environmental Management System.
An audit was performed, Report No. 70770193
Proof has been furnished that the requirementsaccording to
ISO 14001:2004
are fulfilled. The certificate is valid until 2014-04-23Certificate Registration No. 12 104 39456 TMS
Munich, 2011-04-26
Page1of 3
EMS-TGA-ZM-07-92
Dear readers,
Making our products constitutes an upward value chain. Fromwires and optical bers we make cables and cable systems. We
are conscious o our corporate responsibility towards the envi-
ronment and society and are continually stepping up our eorts
in this area. Our plant in Bad Ktzting was Europes rst wire and
strand manuacturer, as long ago as 1996, to be validated pursu-
ant to EMAS.
Since 1998 LEONI has been presenting its environmental peror-
mance in this division in the orm o environmental indicators.
The Wire & Cable Solutions Divisions environmental reports
have since then each covered a period o 4 years. This third envi-
ronmental report covers the years rom 2007 through 2010.
At the end o 2006, 13 LEONI organisational units at 11 locations
in six countries were DIN ISO 14001 certied.
In the meantime we have steadily broadened and improved the
environmental management system at our acilities around the
world. Even during the economically dicult period (rom the
end o 2008 to mid 2009), we prepared more acilities or ISO
14001 certication, where this was obtained or the rst time.
At the time o the editorial deadline in June 2011, a total o 23
LEONI organisational units within the Wire & Cable Solutions
Division in nine countries China, Mexico, the United Kingdom,Slovakia, Turkey, Poland, Hungary, Switzerland and Germany
were thus certied to the ISO 14001 environmental management
standard.
Dr. Klaus Probst Jrgen Kniki
7/27/2019 Environ Leoni
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Enclosure of Certificate No.:
12 104 39456 TMS
Sites Scope of application
LEONIKabelHoldingGmbHStieberstrae5D-91154Roth
Design,development,productionandsales ofwires,cables, cableassemblies,componentsandcable systems
LEONIDrahtGmbHTreuchtlingerStrae20D-91781Weienburg
Design,development,manufactureands aleofcopper andcopper-basedalloyconductors (wire, bunches, braidingwire, strandsandropes)withbare, tinors ilverplatedsurfaces
LEONIDrahtGmbHWindorferStrae1D-93444BadKtzting
Manufactureofcopper andcopper-basedalloyconductors(wire,bunches,braidingwire, strandsandropes) withbare,tin orsilverplatedsurfaces
HaarlnderGmbHRegensburgerRing14D-91154Roth
Manufactureandsale ofstrandedconductors, tinselconductors,braidedcopperstraps, knittedcopperfabrics, wovencoppertapes,earthingtapes andflexibleconnectors withterminals,low-voltage-conductorsand-cables
LEONIKabelGmbHStieberstrae5D-91154Roth
Design,development andmanufacturingofwires, strandedwiresandautomotive& electricalcables
LEONICable(Changzhou)Co.Ltd.FutianIndustryPark, No. 109, HanjiangRoad,XinbeiDistrictPRC-213022Changzhou/ Jiangsu
Design,development andmanufacturingofwires, strandedwiresandautomotive& electricalcables
LEONIKbelgarHungariaKft.KlcseyF.u. 53H-3000Hatvan
Design,development andmanufacturingofwires, strandedwiresandautomotive &electricalcables
LEONICableS.A. deC.V.Ave.Rio Conchos No.9700MEX-31530Cuauhtmoc
Design,development andmanufacturingofwires, strandedwiresandautomotive& electricalcables
LEONIKabelPolskaSp.z o.o.ul.Olawska10, WierzbicePL-55040Kobierzyce
Design,development andmanufacturingofwires, strandedwiresandautomotive& electricalcables
LEONIKabloveTeknolojileriSanayi veTicaretLtd.SirketiBursaSerbestBlgesiTR-16600Bursa
Design,development andmanufacturingofwires, strandedwiresandautomotive& electricalcables
LEONISlowakiaspol.s.r.o.SNP60SK-01851NovDubnica
TrenianskaTepla,astDobrSK-91401Dobr
SK-97228ValaskBel
Design,manufacturingandsales ofcables,cableassemblies,harnesses andpowercord sets.Rewindingandpre-selection ofprecious-metalthreads.Polishingandtesting ofdrawingdies
LEONICable(Xiamen)Co.Ltd.No.666,YangGuangRoadXinYangInd. HaiCangPRC-361022Xiamen
Design,manufacturingandsales ofcables,cableassemblies,harnesses andpowercord sets
Munich, 2011-04-26
Page2of 3
EMS-TGA-ZM-07-92
Enclosure of Certificate No.:
12 104 39456 TMS
Sites Scope of application
LEONIKerpenGmbHZweifallerStrae275-287D-52224Stolberg
Development,productionandsalesof cables,cordsandcompounds
LEONISpecial CablesGmbHEschstrae1D-26169Friesoythe
Designanddevelopment,manufacturing,sales, engineeringservices aswellas servicesrelatedto Cables,Accessories,Assemblies,mechanicalandelectricalComponents, CableHarnesses,CableSystemsand Subsystems forall ApplicationsintheBusinessUnits Telecommunication Systems,HealthcareandIndustrialSolutions
LEONISpecial Cables(Changzhou)Co.Ltd.No. 21TaihuWest Road,NewAreaPRC-213022Changzhou/ Jiangsu
Designanddevelopment,manufacturing,sales as wellasservicesrelatedtoCables, Accessories,Assemblies,CableHarnesses,CableSystems andSubsystemsfor allApplicationsinthe BusinessUnits TelecommunicationSystems,Healthcareand IndustrialSolutions
LEONICableSlovakiaspol.sr.o.Nm. Dr.A. Schweitzera194SK-91601StarTur
Productionof cablesystemsand accessoriesforautomationanddrives,medicaldevices,t elecommunication,aerospaceandmarinetechnologieswithcentralfunctions ofdevelopment andsales inRothandFriesoythe(Germany)
LEONIKabelGmbH-Industrial SolutionsStieberstrae5D-91154Roth
Development,productionandsalesof taylor-madecables
LEONIFiber OpticsGmbHStieberstrae5D-91154Roth
Development,manufacturingandsalesof glas,-POF,-and PCF-fiberopticcables
j-fiberGmbHIm Semmicht1D-07751Jena
Development,ProductionandSales ofOpticalFibersandPreforms;MarketingofKnowhowand TechnicalSupport
j-plasmaGmbHIm Semmicht1D-07751Jena
Im Natal7D-07751Jena
Development,ProductionandSales ofSilicaGlassas wellas SpecialtyPreforms
FiberCoreMachineryGmbHIm Semmicht1D-07751Jena
Development,productionandsellingof manufacturingplantsforproductionof fiberopticcables
Munich, 2011-04-26
Page3of 3
EMS-TGA-ZM-07-92
Environmental report Wire & Cable Solutions 3
The LEONI Group and Wire & Cable Solutions 4
Systematic environmental management 5
Green technology 6
Data collection within the various business groups 9
Business Group Automotive Cables 10
Business Group Industry & Healthcare 12
Business Group Communication & Inrastructure 14
Business Group Electrica l Appliance Assemblies 16
Business Group Conductors & Copper Solutions 18
Summary: Wire & Cable Solutions 20
Outlook 22
Contact 22
Contents
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4 The LEONI Group and Wire & Cable S olutions
Leading cable systems manuacturer
with a global ootprintLEONI operates worldwide, providing wires, optical bers, cables
and cable systems as well as related services or the automotive
sector and other industries. The group o companies market-
listed in the German MDAX index employs about 56,000 people
in 37 countries and generated consolidated sales o EUR 2.96
billion in 2010.
In addition to tailor-made cable solutions, the Group is
increasingly oering its customers complete systems with
perectly harmonised components. Ongoing growth o the
Company as provider o development work and systems is a
signicant trend in this respect.
Synergies thanks to a high real net output ratio
LEONI employees have proound knowledge in cable assembly
as well as a comprehensive understanding o the operating
conditions and technical correlations at the user end. In addition
there is a ratio o real net product output unique in the sector,
which provides valuable synergies: it begins with the nest
single wire and optical ber, moves on to the copper or ber
optic cable and ends with the complete wiring system including
integrated electronics.
Geared to global trends
The Company intends in the uture to benet more rom global
trends. These present the Company with major challenges
because they requently entail greater energy consumption and
environmental harm. At the same time, however, they entail
major opportunities. LEONI is thereore, with its products and
services, preparing or the change involving demography, ecol-
ogy, mobility, globalisation, industrialisation and urbanisation.
Especially with respect to environmental protection, LEONI aims
to become the most innovative cable supplier or the green
technology market.
More inormation is to be ound at www.leoni.com
The LEONI Group and Wire & Cable Solutions
Industry
& Healthcare
Communication
& Inrastructure
Electrical Appliance
Assemblies
Conductors
& Copper Solutions
Automotive CablesCentral Services
Wire & Cable Division
You will nd inormation on the markets in the sections covering the individual business groups.
The Wire & Cable Solutions DivisionThe LEONI Groups structure involves a holding company and
two business divisions. The organisational structure o these
divisions is in essence geared to their customer groups and
markets. The Wire & Cable Solutions Division (WCS) is one o the
two divisions and encompasses all business involving wires and
cables.
Organisation o the WCS environmental
management systems
The person responsible or environmental management in the
LEONI Group is its CEO, Dr Klaus Probst.
Supporting him in the Wire & Cable Solutions Division are the
divisions managing director and as well as the head o the
Central Services department Quality & Environmental Manage-
ment WCS, who is also the divisions designated environmental
management ocer.
All the overarching aspects that concern environmental
management are coordinated rom this department. Examples:
Preparation o environmental reviews, regular obtaining o
relevant environmental indicators (environmental reports) rom
all ISO 14001 certied acilities, extrapolation o environmentalindicators, evaluation o the ndings o internal and external
audits as well as provision o the inormation to all acilities (syn-
ergies). Internal environmental audits are carried on a random
basis also by the WCS Divisions head oce department.
Furthermore, each o the business groups belonging to the
division has its own QM/EM oce, rom where environment-re-
lated matters are coordinated directly within the corresponding
operative organisation. Below that every ISO 1400-certied acil-
ity has the unction o an environmental protection ocer who
is primarily responsible or operational environmental protec-
tion. For the corresponding implementation o LEONIs environ-
mental policy, they set specic environmental targets together
with the plant managers. The acilitys management regularly
reviews work towards these targets as part o an environmental
programme.
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Environmental report Wire & Cable Solutions The LEONI Group and Wire & Cable Solutions 5
Systematic environmental management
The principles o our environmental policy are binding on all
employees as well as on all our business activity.Environmental assets are used at each stage o our produc-
tion processes. Keeping the environmental impact as limited as
possible requires communication and cooperation between the
people involved. Environment-related corporate principles and
targets that serve as a guide to the people involved are essential
to such cooperative eorts. As long ago as 1995, LEONI laid this
down in an environmental policy that is binding on all employ-
ees and accessible to our business partners.
We actively involve our sta in environmental protection. Acting
in an environmentally aware manner is part o every employeesjob. Careul treatment and sparing use o resources, including
separation o waste or example, can work eectively only when
those involved are convinced o the benets. Sta motivation
is essential in this regard. Only when an environmentally aware
attitude is instilled among all employees can measures develop
their ull potential. Extending and promoting the awareness
o responsibility or the environment at all levels is an ongoing
management task.
We shall reduce negative environmental impact to the mini-
mum permitted by using the best available technology that is
economically viable. As early as the design and planning o our
products and processes we ensure that environmental harm is
largely avoided, that emissions and waste are reduced and that
resources are used sparingly.
We undertake to adhere to all pertinent environmental laws and
directives as well as internal rules o conduct. We maintain an
open dialog with customers, authorities and the general public
about issues within our Company that relate to the environment.
We urge our business partners to ollow environmental guide-lines comparable to our own and we advise our customers on
environmentally riendly ways to handle and dispose o our
products.
We regularly evaluate the status o environmental protection
within our Company as well as the technical and organisational
procedures thus required in order to identiy weaknesses, to
initiate the required measures and to document the progress
that has been made.
We raise the level o saety at work by identiying and remov-
ing potential sources o danger to people and the environment.
Health and saety at work as well as environmental protection
are closely interlinked and work practice-related ormulation
o processes usually also results in enhanced environmental
compatibility.
We ensure, with appropriate environmental management, that
our environmental policy is applied eectively.
Environmentally aware thinking that is conveyed to our variouslocations by our environmental management prevails at the
acilities o the Wire & Cable Solutions Division.
Environmental policy at LEONI
We acknowledge that, as a commercial enterprise, we share a
special responsibility or saeguarding the natural essentials o
lie. It is our aim to strike a balance between peoples aspira-
tions, environmental concerns and the interests o our Com-
pany. Environmental protection consequently is a mandatory
element o our business activity at LEONI. Business success and
ecological responsibility are no contradiction in terms or us.
We rate environmental protection among our primary busi-
ness objectives and include it in LEONIs quality policy. The
environmental compatibility o processes and products is raised
by incorporating them in our continuous improvement process
(German abbr.: KVP).
Documented procedures,instructions
Management
manual
Quality & environmental
management
Central Services
Wire & Cable Solutions Division
Holding
Environmental management
representative
Central Services
Business Groups
Central Services
Business Groups
Environmental management
representative
Locations, plants
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6 Green technology
EcologicallyImprovement o environmental perormance through innova-
tive products and solutions o both divisions
Green technology
What exactly does green technology mean?
Also described as environmental technology, the term repre-sents products and services that enable businesses to operate
more energy eciently and be more sparing with resources; to
reduce emissions and thereby to urther increase the environ-
mental compatibility o all their processes.
Demand or environmentally compatible and sustainable
technologies (green technology) continues to rise unabated.
LEONI has set itsel the goal o becoming the most innovative
cable manuacturer or environmentally riendly technologies.
Yet how is green dened?
There is a very avourable trend in green technology es-
pecially or German companies, which in many cases lead the
global market in this respect. Customers are increasingly calling
or green products and ever more environmental legislation
is coming into orce worldwide. The proportion o patents with
reerence to green technology is continually rising. Investors
are also increasingly basing their decisions on how companies
are dealing with the challenges o climate change and environ-
mental protection.
The six global trends o particular importance to LEONI i.e.
the growing population & demographic change, urbanisation,
globalisation, environmental awareness & shortage o resources,industrialisation & automation as well as mobility - present the
Company with both ecological and economic challenges.
We have thus geared our portolio o products and services to
six principal markets or environmental technologies that have,
on the basis o scientic studies, been identied as markets o
the uture.
LEONI does not just pay lip service to sustainability. We are
the rst cable manuacturer to have developed a holistic concept
or green technology. We thus dene all products and system
solutions as well as services that contribute to lowering green-
house gases or serve as a contribution to specic environmental
technologies that control air and water pollution.
In so doing, we rate our activities according to the ollowing
three criteria:
Product: Use o environmentally compatible raw materials
that comply with national and international guidelines Process: Environmental certication o the acilities in our
worldwide production network to ensure optimum energy
and resource eciency in the manuacturing process
Application: Use o our products and solutions in dened
markets to achieve greater energy eciency and CO2 reduc-
tion
Where do we stand with green technology right now?
More than two years ago, both o our divisions extrapolated the
global trends to uture growth areas or LEONI as part o their
strategic planning.
Since 2010 we have successully applied the interlinking o
global trends with our strategy and green technology to posi-
tion LEONI under the motto o mobility and the environment.
We shall continue this or 2011 under the motto o urbanisation
and the environment and will present a urther trend with very
specic solutions by LEONI.
LEONI is making a signicant contribution in three ways
Economically
Strengthening o our customer base through innovative,
technology-driven products and solutions
Socially
Raising the awareness o employees and business partners
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Environmental report Wire & Cable Solutions Green technology 7
Six target markets or green technology
Sustainable mobility
Recycling management
Environmentally
riendly energy generation
and storage
Energy efciency Sustainable
water management
Efciency o raw
and other materials
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8 D at a co ll ec tio n wi th in th e v ar iou s b us in es s g rou ps
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Environmental report Wire & Cable Solutions Data collection within the various business groups 9
Data (quantities produced, consumption and amounts o waste)
is collected consistently and annually across all acilities thathave an ISO 14001-certied environmental management system.
The compression o data is presented hereinater, at both the
business group level and the level o the Wire & Cable Solutions
Division.
In order to chart environmental indicators across the period
rom 2007 to 2010, six ratios were established per business
group. The amount o semi-nished and nished good produced
(wires, cables, bulk cable and cable systems) in each case serves
as the reerence gure as it already did in the previous environ-
mental report.
The ratios we have established are:
Electricity consumption
[kWh] / product [kg]
CO2 emission
[kg] / product [kg]
Other energy sources
(heating oil and gas)
[kWh] / product [kg]
Production waste
(wires and cables; at wire acilities copper waste only)
[kg] / product [kg]
Water consumption
[l] / product [kg]
Waste water
[l] / product [kg]
* Source: Bavarian Environmental Agency Inozentrum UmweltWirtschat,
accessible at http://www.izu.bayern.de/praxis/detail_praxis.php?pid=0203010100217
Data collection within the various business groups
The trajectory o CO2 emissions shown reers to the total energy
consumption (electricity, heating oil, gas as well as, in somecases, district heating) o the individual plants within a business
group.
The respective energy consumption [kWh] was converted into
CO2 emissions [kg]* using the CO2 calculator.
The other energy sources comprise oil and/or gas and, to a
minor extent, district heating. Oil and gas is used or heating and
production at almost all acilities.
It was in many cases not possible to maintain the positive
trend in production waste as planned because o the smaller
batch sizes during the economically dicult time (end o 2008
to approx. mid 2009). This eect is also evident in the energy
consumption trends.
It is attributable mainly to the smaller batch sizes, which
involved more requent ramp-up processes than usual, as well
as very low capacity utilisation in some cases.
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10 Data collection Business Group Automotive Cables
Our Business Group Automotive Cables wide product portolio
covers all the requirements, rom the single-core standard cablethrough to customised solutions, o carmakers as well as the
appliance and lighting industries. To be systematically geared to
market requirements, the business group is subdivided into the
ollowing business units: Automotive Standard Cables, Automo-
tive Special Cables and Electrical Appliance Cables.
Our customers present Business Unit Automotive Standard
Cables with the challenge o making products worldwide
that are largely standardised and o the highest quality or the
automotive industry. As global market leader in single-core
automotive cables with a global production, distribution and
production management network, the business unit supports
its customers with an extensive range o products conorming to
international standards such as ISO, JASO and SAE as well as with
a wide variety o OEM and Tier 1 approvals. We support ecient
work practice through the standardisation o methods and the
clear denition o processes and ensure a consistently high level
o LEONI quality at all production acilities in all corners o the
globe.
Business Unit Automotive Special Cables challenge rom ourcustomers is to bring innovative products onto the market. Our
experienced product specialists maintain close contact with
automotive producers, Tier 1 suppliers as well as connector
manuacturers and also collaborate with experts in international
cable organisations. Our customers thus benet rom know-
how at rst hand. Formulas developed and produced in-house
or insulation materials specically tailored to the automotive
industry and state-o-the-art machines or ram extrusion and
silicon processing as well as covering various orms o crosslink-
ing and oaming processes round o the business units range o
products and services.
Business Unit Electrical Appliance Cables is among the most
signicant suppliers to system manuacturers in the appli-
ance and lighting industry as well as o building wiring and
application-specic special solutions. It is one o the ew cable
manuacturers to have a wide product range that stretches rom
single and multi-core cables harmonised to European standards
through to cables complying with US and Canadian standards.
Working together with our customers in the development o
specic solutions has particularly high priority.
Business Group Automotive Cables
ISO 14001-certied acilities
The ollowing acilities are ISO 14001 certied:Roth (Germany) with 545 employees, Hatvan (Hungary) with
136 employees, Nov Dubnica (Slovakia) with 40 employees,
Wierzbice (Poland) with 295 employees, Gemlik (Turkey) with 61
employees, Changzhou (China) with 115 employees and Cuauh-
tmoc (Mexico) with 200 employees.
The plan or the medium term is to prepare the two acilities in
Halver (Germany) with 62 employees and in Casablanca (Mo-
rocco) with 35 employees or ISO 14001 certication.
Highlights o the environmental management system
The ollowing acilities were certied to the ISO 14001 envi-
ronmental management system or the rst time during the
period under report: Nov Dubnica (Slovakia) in November
2007, LEONI Kabel Turkey in December 2007 and Changzhou
(China) in June 2009
Set-up o a Business Group Automotive Cables environmental
indicators system
The individual acilities o our business group applied various
new measures to achieve ar-reaching and sustained environ-
mental conservation, such as Cisterns
Cooling systems, cooling towers and cooling water insula-
tion systems
Improvement o waste water technologies and water treat-
ment systems
Measures to improve emulsion ltration
New, improved drive technologies on the production lines
PVC recycling o waste materials o value
Energy saving lighting technology
Improvement o the smoke alert system
A more ecient steam generator
Systems to recover exhaust gases
Noise insulation cabinets
Investment in measuring equipment to check the com-
pressed air network, emissions and pollution involving
noise and air
Peripheral equipment, or example investment in com-
pressed air regulation, conveyor equipment or new
transport and logistic systems, waste separation systems
and insulation systems
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2007 2008 2009 2010
0.8
0.6
0.4
0.2
0
Electricity consumption [ kWh / product kg ]
2007 2008 2009 2010
3.5
3.0
2.5
2.0
1.5
1.0
0.5
0
Water consumption [ l / product kg ]
2007 2008 2009 2010
Other energy sources 1 [ kWh / product kg ]
2007 2008 2009 2010
Waste water [ l / product kg ]
2007 2008 2009 2010
Production waste 2 [ kg / product kg ]
2007 2008 2009 2010
0.8
0.6
0.4
0.2
0
CO2 emission [ kg / product kg ]
1 Heating oil / gas
2 Wires and cables
0.20
0.15
0.10
0.05
0
0.08
0.06
0.04
0.02
0
3.5
3.0
2.5
2.0
1.5
1.0
0.5
0
11Environmental report Wire & Cable Solutions Data collection Business Group Automotive Cables
The environmental indicators
All processes in this business group certainly merited avour-able presentation. Success was mostly also evident in terms o
waste minimisation. At only a ew acilities did the switchover to
a product portolio geared to specialist customers, longer test
phases as well as smaller batch sizes exert the opposite eect.
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12 Data collection Business Group Industry & Healthcare
Business Group Industry & Healthcare
The range o Business Group Industry & Healthcares products
and services covers, via its Business Unit Industrial Solutions,virtually all industrial sectors such as actory automation, drive
technology, robotics, measurement and control technology /
sensor technology.
Our product portolio here stretches along the entire value
chain o our Company - rom strands and special bers to cable
solutions that conorm to national and international standards,
application-specic special cables and ber optic conductors
through to complex systems solutions and tailor-made services.
Business Unit Healthcare supplies leading manuacturers
worldwide o medical devices and apparatus as well as patient
monitoring equipment and medical laser technology. As a pro-
vider o development services and systems, we also oer laser
probes and endoscopy components in addition to special cable
solutions, cables and sub-systems.
The many years o experience and extensive skills o Business
Unit Telecommunication Systems lie in the manuacture o co-
axial and symmetric cable solutions, high-requency and switch-
board cable as well as high-speed data cables and complete
cable systems with passive and active transmission elementsin the areas o mobile networks, xed network technology and
computer centres.
Business Unit Fiber Optics is a leading provider o ber optic
cables or special applications in industry, sensor and analysis
systems, science, communications as well as in medical laser
technology.
We have a unique product portolio at each link in the value
chain: rom the perorm and the bers drawn rom it through to
ber optic cables and complete ber optic systems with optical
components developed in house.
Business Group Industry & Healthcare has a total o 34 acilities
with more than 2200 employees worldwide. Mostly these are in
Europe with 23 locations, 16 o them in Germany. Furthermore,
there are ve acilities in USA/Canada as well two locations in
Asia.
ISO 14001-certied acilities
The Friesoythe acility was already ISO 14001 certied in 1996;Stara Tura (Slovakia) ollowed in 2007. The Changzhou (China)
and Roth (Germany) acilities were certied in 2005 and 2002, re-
spectively. The three subsidiaries J-Fiber GmbH, J-Plasma GmbH
and FiberCore Machinery Jena GmbH Jena have been EMAS
certied since 1999, 2007 and 2008, respectively.
Highlights o the environmental management system
Thanks to steadily raising the environmental awareness o sta
at all plants o Business Group Industry & Healthcare, consider-
able potential or savings on water and electricity consumption
has been released and a signicant reduction in waste quantities
achieved over the past ew years.
Meriting particular mention along with these successes is
also the re-use o plastic materials in cable production by way o
in-house recycling measures as well as various process improve-
ments aimed at saving material at all acilities.
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1 Heating oil / gas
2 Wires and cables
2007 2008 2009 2010
1.2
1.0
0.8
0.6
0.4
0.2
0
Electricity consumption [ kWh / product kg ]
2007 2008 2009 2010
2.5
2.0
1.5
1.0
0.5
0
Water consumption [ l / product kg ]
2007 2008 2009 2010
Other energy sources 1 [ kWh / product kg ]
2007 2008 2009 2010
Waste water [ l / product kg ]
2007 2008 2009 2010
Production waste 2 [ kg / product kg ]
2007 2008 2009 2010
1.2
1.0
0.8
0.6
0.4
0.2
0
CO2 emission [ kg / product kg ]
0.6
0.5
0.4
0.3
0.2
0.1
0
0.08
0.06
0.04
0.02
0
2.5
2.0
1.5
1.0
0.5
0
13Environmental report Wire & Cable Solutions Data collection Business Group Industry & Healthcare
The environmental indicators
The main reason or the increase in electricity consumptionand other energy sources in the years rom 2009 is the shit
away rom large volume products and heavy FlexLine ones. The
products made instead involve a ar larger number and more
complex work steps. Furthermore, a new heating system as well
as additional, high power consuming compressors went into
operation at our Chinese acility in 2008.
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14 Data collection Business Group Communication & Inrastructure
Business Group Communication & Inrastructure
Our value chain in the Communication & Inrastructure segment
ranges rom conception and planning to the development andproduction o copper cables and optical bers as well as data ca-
bles and connection components through to complete systems
and services.
The cables and insulation materials o Business Unit Inrastruc-
ture & Datacom are a recognised standard in public buildings,
in structural and civil engineering as well as in trac inrastruc-
ture systems.
In the datacom segment we also oer, in addition to oce
wiring (LAN Oce), cables or industrial buildings (LAN Industry),
computer centre equipment (Data Center) as well residential
wiring (LAN Home).
The international project business is one o the ocal areas in our
Business Unit Industrial Projects. You will nd this units cables
used in numerous projects around the globe. Some o these pro-
jects are smaller; some ser ve huge plants, quite oten cover ing a
period o several years.
The cable solutions o our Business Unit Solar & Wind Power
are exceptionally varied. Our greatest attention here is on the as-pects o saety, resistance to aggressive media and temperature,
size optimisation and weight reduction. We realise this with a lot
o know-how in our development laboratories and with a high
degree o vertical integration. We achieve higher quality with
very good physical and electrical values by means o electron
beam crosslinking on our own lines.
Business Unit Trafc oers customised and rst-rate cable
solutions that meet the special demands o ship and marine
engineering.
With the extensive portolio o products and services or
internal and external wiring o rolling stock we will support you
across the entire liecycle o your vehicles.
For complex applications in industry and the inrastructure
sector involving airports and airlines our core areas o expertise
lie in the development, design, manuacture and distribution o
high quality cables and conductors.
Business Unit Irradiation Services is one o the largest Euro-
pean service providers in the eld o crosslinking and modiy-
ing plastics, sterilisation and similar applications with help oelectron beams and gamma rays.
At present, our acility in Dniken, Switzerland, which employs
about 100 people, has seven electron accelerators with powerranging rom 0.5 to 10 MeV as well as one pallet gamma sterilisa-
tion line. An additional sterilisation line that is based on x-rays
was commissioned in 2010.
Our newly established acility in Bautzen, eastern Germany,
runs an electron accelerator. A second accelerator is already in
the process o being set up.
Innovative technologies will saeguard tomorrows energy
supply. Our Business Unit Energy & Communication makes the
connection or the uture - global energy supply is one o the
major challenges o the immediate uture. Renewable energy
sources have to be developed and new standards have to be
established. We are conscious o this task and are committing
ourselves with innovations, quality products and services or
ecient energy generation and distribution.
ISO 14001-certied acilities
Our locations in Stolberg (Germany) und Dniken (Switzerland)
are already ISO 14001 certied.
Our acilities in Hard (Switzerland), Riedstadt (Germany),
Bautzen (Germany), Codogno (Italy) and Monticelli dOngina(Italy) are not yet ISO 14001 certied.
Highlights o the environmental management system
Our Stolberg acility was commended or ECOPROFIT
operation in the Aachen region in 2009
Lighting management old, conventional technology
replaced with modern, electronically-governed equipment.
A centralised energy management system was set up
Use o thermostat-controlled switch cabinet ventilators
Sta involved in the environmental management system
by way o training sessions and an ideas competition
Systemic start-up scrap reduced by optimising processes and
technology
The need or action to carry out energy-related buildings
reurbishment examined ater evaluating gas consumption,
as compared with the degree day gures
Plastics recycling improved
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2007 2008 2009 2010
Production waste 2 [ kg / product kg ]
0.08
0.06
0.04
0.02
0
15Environmental report Wire & Cable Solutions Data collection Business Group Communication & Inrastructure
1 Heating oil / gas
2 Wires and cables
2007 2008 2009 2010
1.0
0.8
0.6
0.4
0.2
0
Electricity consumption [ kWh / product kg ]
2007 2008 2009 2010
12.0
10.0
8.06.0
4.0
2.0
0
Water consumption [ l / product kg ]
2007 2008 2009 2010
Other energy sources 1 [ kWh / product kg ]
2007 2008 2009 2010
Waste water [ l / product kg ]
2007 2008 2009 2010
1.0
0.8
0.6
0.4
0.2
0
CO2 emission [ kg / product kg ]
0.60
0.50
0.40
0.30
0.20
0.10
0
12.0
10.0
8.06.0
4.0
2.0
0
Select environmental indicators
The main reason or the increase in specic consumption withinBusiness Group Communication & Inrastructure was the smaller
number o orders received or various products, thus resulting in
less capacity utilisation.
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16 Data collection Business Group Electrical Appliances Assemblies
Business Group Electrical Appliance Assemblies
Business Group Electrical Appliance Assemblies is a proven and
innovative partner to the electrical goods and lighting indus-try. Based on an international development, production and
distribution network we oer our customers around the world
an extensive range o cables, power cords and ready-to-install
wiring harnesses or electrical appliances. Our steadily grow-
ing range o assembled cables meets all pertinent national and
international standards and has been recognised by well-known
national certication bodies around the world, such as VDE,
KEMA, UL, UK, CCC, etc.
Business Group Electrical Appliance Assemblies is one o the
ew cable manuacturers to oer a comprehensive selection
o products or the household appliance and lighting industry,
which ranges rom single and multi-core harmonised cables
compliant with European standards to more than 600 dierent
kinds o UL and CSA-approved cables, which are the US and
Canadian standards, respectively. LEONIs top quality character-
ises all o our products, regardless o whether they are made to
standard or customised specications.
Overview o our customer base:
BSH Bosch and Siemens Home Appliances
Electrolux Philips
Miele
Black & Decker
Vorwerk
Bosch
Panasonic
Toshiba
Thanks not least to the commitment o our 2500 employees,
Business Group Electrical Appliance Assemblies to a large
extent implemented the ISO 14001-compliant environmental
management system and steadily broadened it. The ISO 14001
environmental standard was already established years ago at the
relevant production sites.
ISO 14001-certied acilities
Business Group Electrical Appliance Assemblies produces at ourlocations (one plant in Slovakia, two plants in China and one in
Spain). Two o these production acilities (LEONI Xiamen in China
and LEONI Nova Dubnica in Slovakia) are ISO 14001 certied.
We are aware o the responsibility we share and protect natural
resources as well as the oundations o lie. Our aim is to strike
a balance between respect or nature and achieving business
objectives. Environmental protection is a key element o our
Companys activity.
Highlights o the environmental management system
By adjusting the size o sea containers used at our Chinese
acilities we achieved savings in logistics o between 15 and
more than 30 percent.
In collaboration with various household appliance manuac-
turers, Business Group Electrical Appliance Assemblies has
developed environmentally-riendly, halogen-ree assembled
cables and launched its LEONI EcoSense trademark in 2010.
By making use o waste heat rom compressors at our
Slovakian acility we managed to heat processing water on a
permanent basis as well as to eed excess heat into building
heating during the winter. This achieved substantial savingson electrical energy.
We realised urther energy savings by means o cooling water
management that is geared to the outside temperature.
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1 Heating oil / gas
2 Wires and cables
2007 2008 2009 2010
0.8
0.6
0.4
0.2
0
Electricity consumption [ kWh / product kg ]
2007 2008 2009 2010
1.4
1.2
1.0
0.8
0.6
0.4
0.2
0
Water consumption [ l / product kg ]
2007 2008 2009 2010
Other energy sources 1 [ kWh / product kg ]
2007 2008 2009 2010
Waste water [ l / product kg ]
2007 2008 2009 2010
Production waste 2 [ kg / product kg ]
2007 2008 2009 2010
0.8
0.6
0.4
0.2
0
CO2 emission [ kg / product kg ]
0.08
0.06
0.04
0.02
0
0.04
0.03
0.02
0.01
0
1.4
1.2
1.0
0.8
0.6
0.4
0.2
0
17Environmental report Wire & Cable Solutions Data collection Business Group Electrical Appliances Assemblies
Select environmental indicators
Business Group Electrical Appliance Assemblies, in particular,is able despite the dicult situation in 2009 to report an on-
the-whole positive trend in its gures.
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18 Data collection Business Group Conductors & Copper Solutions
Business Group Conductors & Copper Solutions
Business Group Conductors & Copper Solutions is represented by
LEONI Draht GmbH, based in Weissenburg, Bavaria. With its a-cilities, it has an international production network making wires
and strands o copper, galvanic-plated copper and copper alloys.
These products are used in all segments o electrical engineer-
ing: in the automotive industry, electric and electronic systems,
telecommunications, the solar industry, energy technology, data
technology, medical technology, high-requency technology,
military technology as well as in aerospace engineering.
Environmentally riendly growth and ecological responsibility
are refected not only in our use o environmentally compatible
production methods, but also in the development o products
that are optimised to save energy and or the use o renewable
energy sources.
Accordingly, the ocus in the area o electric conductors is on
designing strands in concentric and semi-concentric structures
that are especially round as well as on miniaturisation through
the use o high-strength alloys. During urther processing in the
cable industry, these materials provide savings on insulation
material and weight and consequently reduce the CO2 emissions
o vehicles, or example.
With our new production area or fat wires or the solar indus-
try (cell and string connectors or photovoltaic modules) we aremaking our contribution to urther development in the use o
renewable energy sources.
We also manuacture highly fexible, fat copper tapes, ropes
and braids, which are used in the production o carbon brushes
and welding equipment as well as increasingly also in wind
turbines and electric vehicles.
Alongside the modern, ecient materials or industry, we
continue to this day to also make the traditional Lyonese wares,
such as gold and silver-plated threads, bullion wire and stitching
wire or precious embroidery.
ISO 14001-certied acilities
Our acilities in Weissenburg (Germany) with 200 employees,
Bad Ktzting (Germany) with 140 employees, Roth (Germany)
with 23 employees and Cinderord (United Kingdom) with
90 employees are already ISO 14001 certied.
Highlights o the environmental management system
Measures to save precious resources have or years alreadybeen driven orward hand in hand with improvement o working
conditions and also with optimisation in averting threats at all
acilities.
Improving energy eciency is a constant ocal point. Conse-
quently, our acility in Roth, or example, gradually introduced
more energy-ecient lighting, while the Weissenburg plant
optimised compressor control.
Just as much attention is devoted to consumption o heat
energy and thereore o ossil uels. Savings were achieved by
eeding the heat expelled by the production process back into
the heating system by means o heat recovery systems.
Heat losses and areas exposed to the potential threat o re
were identied by conducting thermographic surveys. Weak
points ound in the process were eliminated. Workshops contrib-
ute to raising the awareness o sta while large-scale re drills
are part o emergency preparedness.
Water is the oundation o all lie on earth. Sparing use o
this precious resource is thereore a key element in the area o
environmental management. The demand or drawing emulsion
is lowered through the use o modern ltration systems. Fresh
water consumption, as well as the disposed amount o wasteemulsion, consequently also dropped. One o our acilities makes
use o rain water by catching it o the roo o a building exten-
sion and eeding it into the cooling water cycle. This also eases
the burden on the municipal sewage treatment plant.
Fresh air and low noise are given high priority at all o our
acilities. As a matter o principle, new production lines are
thereore tted with noise protection cabins and exhaust sys-
tems with silencers. A ventilation system at our acility in
Bad Ktzting is capable o completely exchanging all the air
o a production shop 7 times an hour, thereby providing
better ambient conditions.
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1 Heating oil / gas
2 Copper (will be fully recycled)
2007 2008 2009 2010
2.0
1.5
1.0
0.5
0
Electricity consumption [ kWh / product kg ]
2007 2008 2009 2010
1.6
1.2
0.8
0.4
0
Water consumption [ l / product kg ]
2007 2008 2009 2010
Other energy sources 1 [ kWh / product kg ]
2007 2008 2009 2010
1.6
1.2
0.8
0.4
0
Waste water [ l / product kg ]
2007 2008 2009 2010
Production waste 2 [ kg / product kg ]
2007 2008 2009 2010
2.0
1.5
1.0
0.5
0
CO2 emission [ kg / product kg ]
0.4
0.3
0.2
0.1
0
0,10
0.08
0.06
0.04
0.02
0
19Environmental report Wire & Cable Solutions Data collection Business Group Conductors & Copper Solutions
Select environmental indicators
The commissioning o high-tech machinery (tin-plating line orsolar braids; multi-wire drawing line or nickel-plated wires) as
well as setting up o high power consuming plant (rolling mill)
temporarily causes less productive circumstances. Yet this re-
quires resources such as electrical power and water, which is why
these key indicators are partly on a downward trajectory.
Drawing processes involve high power consumption and cause
waste heat, which in the winter months is used to heat the pro -
duction shops. During the period o weak capacity utilisation
rom the end o 2008 to early 2009 this eect had to be com-
pensated with more use o oil and gas. Consumption o other
energy sources was thereore up.
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2003 2004 2005 2006 2007 2008 2009 2010
0.6
0.5
0.4
0.3
0.2
0.1
0
2003 2004 2005 2006 2007 2008 2009 2010
5.0
4.0
3.0
2.0
1.0
0
2003 2004 2005 2006 2007 2008 2009 2010
0.8
0.6
0.4
0.2
0
Electricity consumption [ kWh / product kg ]
Water consumption [ l / product kg ]
CO2 emission [ kg / product kg ]
Waste water [ l / product kg ]
2003 2004 2005 2006 2007 2008 2009 2010
5.0
4.0
3.0
2.0
1.0
0
20 Summary
The previous environmental report, which covered the period
rom 2003 to 2006, already showed a positive trend not only inthe Wire & Cable Solutions Divisions energy eciency.
This uptrend continued in the period rom 2007 to 2010 and is
presented accordingly in the current environmental report.
Summary: Wire & Cable Solutions
Comparison o Wire & Cable Solutions key indicators
The ratio o CO2 emissions [kg] to product [kg] was down by
7.3 percent in the period rom 2003 to 2006. In the subsequent2007 2010 reporting period the CO2 gure was down by as
much as 12.2 percent.
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Environmental report Wire & Cable Solutions 21
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22 Outlook Contact
This Environmental Report advises the public, especially our
customers and employees, on our environment-related activity.Please eel ree to contact us i you have any questions or sug-
gestions concerning this topic.
We will answer any o your questions concerning the environ-
ment and energy that you email to: [email protected].
This report is available or download (also in German) to all
interested persons and groups rom our website at www.leoni.
com.
You will nd urther inormation on the subject o the environ-
ment on our website.
Energy:
Production requires energy!It will in the uture become increasingly important, in the wake
o steadily rising energy demand, to give greater weight to the
subject o energy management, which is tied closely to the
subject o environmental management.
This means not losing sight o diering actors always rom
a commercial aspect. The principle is to consider renewable en-
ergy not only when buying electrical power or to always acquire
the best possible technology with respect to production plant,
but also to take a structured approach in continual execution o
energy-saving projects.
Energy eciency means, at constant output, reduction o
the energy used by means o continual improvement o various
processes.
Sustainability:
LEONI denes sustainability as working in a commercially,
environmentally and energy aware manner. This includes the en-
vironmental compatibility o products as well as the behaviour
o all employees with respect to environmentally aware dealing
with all resources. With respect to the development opportu-
nities o upcoming generations, we also call or and supportsustainability in the area o research and development.
Copper:
The raw material o copper is one o the main components o
our products. That is why we vigorously pursue raw material e-
ciency in this respect. We continually strive towards minimising
production waste in our everyday work.
Insulation materials:
Insulation materials are another key element. We develop and
produce cable insulation compounds in line with legal require-
ments (REACH, RoHS) and according to customer specications
with respect to banned substances.
In addition, we have developed compounds in which ecologi-
cally dubious elements have been substituted. Future insulation
materials will have more avourable properties; along with being
fame retardant and partly sel-extinguishing, the compounds
are halogen ree and resistant to mechanical strain.
Outlook Contact
About
Published by: Wire & Cable Solutions division
Conceptual design / editor: Eva Schuster
Coordination: Karl-Heinz Brkel
Quality & Environmental Management
Dated: June 2011
Our special thanks go to all colleagues who contributed
to preparing this report.
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Environmental report Wire & Cable Solutions 23
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Stieberstrasse 5
91154 Roth
Germany
Phone +49 9171-804-0
Fax +49 9171-804-2200E-mail [email protected]
www.leoni.com
LEONI Kabel Holding GmbH