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Seite 1 I Resource Efficiency by VDI | December 2012 | Werner Maass © VDI Zentrum Ressourceneffizienz GmbH

The VDI Centre for Resource Efficiency

A Competence Centre for SME

12th December 2012


An institution of the Association of German Engineers (VDI)

VDI (since 1856)

About 150.000 members 12.000 active experts

VDI-Group

12 VDI- Societies60 Technical Divisions Education

ca. 200 new and revisedVDI guidelines per year

Innovation funding Technology Consulting Media Advanced Training


Institutional Context of VDI ZRE

VDI Centre for Resource Efficiency(VDI ZRE)

■ project cooperation of the German Ministry for the Environment (BMU)

■ and the Association of German Engineers

■ funded in the framework of the National Climate Initiative of BMU.

VDI GmbH

VDI Group

VDI e.V.

VDI Verlag GmbHSpringer-VDI-Verlag GmbH

VDI Zentrum Ressourceneffizienz

GmbH

VDI Wissensforum GmbH

VDI Technologiezentrum GmbH


Promoting the realisation of resource-efficiency (RE) concepts inrelevant practical fields of technical applications aiming at:

Reducing the consumption of natural resources

Increasing the competitiveness of German SME

via applications of innovative technologies and processes

Focus: Manufacturing and Construction

ScienceTechnology VDI ZRE

VDI ZRE – The Mission


Raw Material Usage: 1979: 35 Bill. t 1989: 41 Bill. t 1999: 49 Bill. t 2009: 68 Bill. t 2050: 120 Bill. t ?

Driver: growth of the population

prosperity

Limitation of resources

Quelle: Krausmann et al. (2009): Growth in global materials use, GDP and population during the 20th century, Ecological Economics Vol. 68, Nr. 10, 2696-2705, Version 1.2 (August 2011), www.uni-klu.ac.at/socec/inhalt/3133.htm

1900

1910

1920

1930

1940

1950

1960

1970

1980

1990

2000

2006

2008

-

10,000,000

20,000,000

30,000,000

40,000,000

50,000,000

60,000,000

70,000,000

80,000,000 Global Raw Material Usage

Bauminerale

Erze & Industrieminerale

Fossile Energieträger

Biomasse

Ro

hst

off

entn

ahm

e in

TS

D T

on

nen


BGR DE (Bundesanstalt für Geowissenschaften

und Rohstoffe): From the geological point of view there is no limitation of the supply of minerals and ores.Shortages are only a short- or midtime matter

There will be higher price level by the strong demand of the BRIC states.

Quelle: BGR, 2012; http://www.bgr.bund.de/DE/Themen/Min_rohstoffe/Rohstoffwirtschaft/rohstoffwirtschaft_node.html

Limitation of resources


RESOURCE EFFICIENCY (RE) AT SMES


Resource Efficiency (RE) at SMEs

Materials are the main cost factor in the manufacturing sector

Personal costs are less than 20%

Decreasing material costs is the way to strengthen the

company and Support climate

protection

Material44%

Energy2%

Goods for Resale11%

External Suppliers

2%

Staff18%

Taxes3%

Interest1%

Other (Write-Offs Rental

etc.)19%

Cost StructureManufacturing Sector

Source: Federal Statistical Office Germany, 2009



Aim: increase in profit by 25%

Two Possibilities

turnover increase by

material cost decrease from

Other53%

Material Cost44%

Profit3%

Cost Effectiveness of RE Measures

Decrease in material cost by 1,7% leads to 25% more profit

25%

44% to 42,25%



reduced machining operation by 1800%, 68% less material and 89% less waste

Fabrication out of precast molding blank

Chipping out of full block



1/3 less cost for natural gas; 200,000 l/a less sewage water – ROI 2 years

Food industry

Source : Pfaffmann.de; own



>50% less costs for tool; 65% less energy; cost reduction >30%



75% less material; 75% less energy; cost reduction >30%


Quelle: VDI ZRE (2011)

Production of goods and energy

Savings by: Production focussed logistics (Kanban)

Contineous quality audits

Energy by: efficient IT infrastructure Heating by wood Windenergy Photovoltaik Run-of-river station

Results: 25 % more Energy

New Productionlines: Energy Plus Factory


15

Funding investments in resource efficient production lines by the public bank KfW

Example: Replacement of a old printing machine by a new one.

Investment: 11,000,000 EUR

Advantage for the environment*:

Paper: -2.839 t/a

Colour/Alcohol: -87 t/a

Electricity/Gas: -13 Mio. kWh/a

CO2-emissions: -6.347 t/a* based on the same production level

Advantage for the company:

Paper: -1.930

KEUR/a*

Colour/Alcohol: -143

KEUR/a*

Electricity/Gas: -680

KEUR/a*

more capacity

flexibel product design

Financing new technologies for resource efficiency


Resource Efficiency (RE) at SMEs - RE at Work

Results from consultancies since 2007 Net profit ratio: +2,5 % Cost reduction: 220,000 € per year Pay back time: 1-2 Years Half of the efficiency measures can be directly implemented with an

investment of less than 10.000 €


relased by the federal goverment on 29.02.2012

Goals: - Decoupling economical growth

from resource usage

- Minimizing environment impacts

- Responsibility for consumption of resources

- Strengthen the competiveness of the German industry

German Resource Efficiency Program (Deutsches Ressourceneffizienzprogramm (ProgRess)


HOW TO CONVINCE SMES TO IMPLEMENT RE


Resource Checks DatabaseProcess chains

Efficiency map Movies QualificationVDI-Handbook Resource Efficiency in Kooperation mit dem VDI e.V.

Innovation radar

VDI ZRE Products and Projects


RE map with information about:

Experts specialized in RE consultancy

Best practice examples

Movies about exemplary solutions for SMEs

Funding for RE investment

Efficiency map


Online and offline versions

Resource Checks

Manufacturing

Basis moduleMetal processing

Polymer processing

Varnishing Shape cutting Electrocoating

Foundry technology

Cold rolling Hot rolling

Construction

Facility Management(Hospital)

Energy-efficient Renovation(Hospital)

Lifts


Showing RE potentials along a process chain. Available RE knowledge is linked to dedicated sub processes.

Example: Process Chain Foundry Technology

Process Chains


Web-based video-magazine: www.ressource-deutschland.tv or www.resource-germany.tv

Movies are produced and released at regular intervals (currently 19 films are available)

Best practice examples are filmed at SMEs

resource efficient processes are explained by 3D animation

Web Video Magazine

http://www.ressource-deutschland.tv/

http://www.resource-germany.tv/


Handbook VDI Guidelines for RE

VDI 4597

Rahmen

VDI 4598RE in KMU

VDI 4599KRA

VDI 4600KEA

Methodische Grundlagen der Bewertung von Ressourceneffizienz

Branche 1

Anwendung

VDI-BranchenleitfädenKennzahlen

Produktionsintegrierter Umweltschutz

Richtlinien zu Einzelfragen

VDI 2243

VDI 2343

VDI 4070

VDI 4075-1

Branche 2

Branche 3

VDI 4075-2

VDI 4075-3

VDI 4661

VDI …

VDI …

VDI …

VDI 4601

UI

Branche …

VDI 4075-x

existing

planned

in progress

1

2

3

© V

erei

n D

euts

cher

Ing

enie

ure

(201

1)

Richtlinien-Screening (im Rahmen der turnusmäßigen Überprüfung)In cooperationwith VDI e.V.


www.qualifizierung-re.de

Theoretical Introduction to RE (3 days)

RE through ecodesign Methods and instruments for analysing and improving RE in the

production process Innovation coaching

Practice module (2 days)

Practical application of theory Plant tours Guided expert dialogue

Qualification course Resource Efficiency (RE)


Goal of the campaigne: „Triple win“-Potential for RE at SMEs: 1. Strengthen the competiveness by cost reduction 2. safeguarding industry's competitiveness 3. Environmental protection

Duration: 2 years

Schedule: 2011 - 2013 website www.das-zahlt-sich-aus.de since Nov. online

Campaign „Competitive edge by Resource efficiency“

http://www.das-zahlt-sich-aus.de/






Plan for 2013• exhibition• booth concept for local activities• …… Interaction.

Cooperation with local partners like chambers of commerce, unions etc.



VDI Zentrum Ressourceneffizienz GmbHJohannisstr. 5-6 D-10117 Berlin +49 30 27 59 506-0

[email protected]

http://www.vdi-zre.de/

mailto:[email protected]

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