NI Chamber Energy Forum 2016/2017 Inclusive value chain redesign - PowerPoint PPT Presentation

NI Chamber Energy Forum 2016/2017 Inclusive value chain redesign Ton van Keken SVP Operations EMEA 1

• Inventor of modular carpet • Nasdaq listed • Sales $1,1 billion • Employees 3.800 • 6 Factories on 4 continents

“One day people like me will go to jail” Ray Anderson Oprichter, Interface

Journey to Zero: The seven fronts REDESIGN COMMERCE SENSITISING STAKEHOLDERS RESOURCE EFFICIENT TRANSPORTATION CLOSING THE LOOP RENEWABLE ENERGY BENIGN EMISSIONS ELIMINATE WASTE

Transparancy 68 % 9 % 8 % 8 % 7 % Raw Interface Interface Use & End of Life Materials Manufacturing Transportation Maintenance

68 % 9 % 8 % 8 % 7 % Raw Interface Interface Use & End of Life Materials Manufacturing Transportation Maintenance

Biomimicry – Learning from nature 11

Towards zero installation waste using Random Design Average wastage Broadloom 12% Normal Random carpet tile carpet tile 3 - 4% 1 - 2%

Three ways to reduce the biggest impact of a carpet tile: Use less yarn Use recycled yarn Invent a new yarn

14 Use less yarn Microtuft: Around 50% less yarn

ReUse Social hubs-sorting: • Reuse • Recycling • Waste-to-energy ReEntry Hub Veenendaal, the Greenstream Recycling, Wales Netherlands

ReEntry 2.0 recycling Scherpenzeel Insert background Image here

Fluff Separated

Recycled backing crumb

Aquafil’s yarn is made with 50% pre-consumer and Fishing nets to carpet 50% post-consumer recycled material

Networks

Philippines and Cameroon

Invent a new yarn 63% bio-based yarn Fotosfera is our first product using bio- based nylon yarn

TacTiles™ • Glue-free installation • Virtually zero VOCs • Fast, clean and easy • Eases re-use and recycling 24

RECYCLED PVB ADHESIVE • Recycled content • Cost advantage conf nfide idential ntial

Pathways to 2020 - What’s Left to Be Done FACTORIES TO ZERO PEOPLE 2020 SUPPLIERS TO ZERO PRODUCTS TO ZERO

Factories to Zero 3 Goals 92% 84% 45% NOW Zero non Zero waste Zero process 91% renewable will leave our water in energy factories manufacturing 87% 27

Energy: sustainability and costs SPZ: Plant in Scherpenzeel, The Netherlands Cav: Plant in Craigavon , NI Year Electricity SPZ Electricity CAV Electricity total Gas SPZ Gas CAV Gas total 2015 9.040.656 kWh 1.625.998 kWh 10.666.654 kWh 1.420.908 m² 92.778 m² 1.513.686 m² Electricity SPZ Costs Electricity CAV Costs Electricity total costs Gas SPZ Costs Gas CAV Costs Gas total costs Total energy cost € 813.659 € 146.340 € 959.999 € 554.154 € 36.183 € 590.338 € 1.550.336 28

Thermal isolation project 22.000m3 annual gas usage reduction

LED lighting

New pre-coat line 360.000m3 annual gas usage saving New pre-coat manufacturing line Our new Pre-coat process consumes 50% less gas per m 2

Heat Recovery From The Compressed Air System By recovering rejected heat and reusing it in our factory heating cycle allowed us?  To further improve the overall efficiency of the compressed air system  To reduce our factory`s total energy heating consumption by 28% 32

Project CEA-EU-0017 New GA55kw VSD Atlas Capco Air compressor Installed Recover Heat From Compressor & Duct into factory  Heat outlet ducting Installed from the compressor into the factory which creates an invisible warm air curtain reducing the factory's heating costs 

2016 Savings Up To Wk32 5 ° c 20 ° c Frequent open & close operation of the speed door

Factories to Zero Renewable Energy Leadership 92% 84% 45% NOW 91% 87% 35

Green gas Netherlands: Biogas from fish waste

Factory & Warehouse Proposal CLINT Reversible Heat Pump Air / Water System 570 Kwh Heating Energy & 490 Kwh Cooling Energy  Uses Non – Ozone depleting refrigerant R410A  Heating Energy 570 Kwh / Cooling Energy 490 Kwh  100% Green Electricity  RIF : Power factor Correction 15% reduction of input current  Electronic soft start reduces starting current by 30%  Permits operation in the winter & summer with external temps dropping to -20 oC & rising to 50 oC Our electricity is 100% renewable therefore the heat pumps have no impact on the environment. The heat which the heat pump extract`s from the air, is constantly being renewed naturally 37

Annual Energy Efficiency Gain Current Natural Gas Heating Total Kwh 1,046,259 Kwh Gas cost per kwh 0.05 Natural Gas cost GBP £52,300.00 Green Electricity Heat Pump Total Kwh 331,793 Kwh Cost per kwh 0.10 Total Green Electricity Cost : £33,179.00 Positives Kwh % reduction 46% GBP £ Gain £19,000 Please *note projected costs are based on current market share prices*

Ultrasonic cutting ‘window waste’ with die cutting ‘window waste’ with ultra sonic cutting Carpet Die cut Tiles Carpet Ultra Sonic cut Tiles 6 cuts + waste 1 cut + waste

Water in closed circuit

Supplies to Zero We Can’t Do This Alone Zero Virgin Zero Chemicals of Zero Materials Concern Carbon Footprint

Products to Zero 4 Goals 92% 84% 45% NOW Zero carbon Zero virgin Zero Reuse/ReEntry 91% footprint raw materials chemicals in every market of concern 42

Technology-led carbon reductions in carpet

Ecometrics, Dec 2015 50% 92% reduction 50% raw reduction materials in green house in product recycled or gas emissions carbon biobased footprint

0 waste will leave our factories Global projections 2020 95% reduction in green house gas emissions 95% raw materials recycled or biobased 80% reduction in product carbon footprint Carpet take-back available in every market

Business case for sustainability • Competitive advantages: proposition, design, function • Productivity gains (eg. energy, waste) • Internal engagement • Recruiting • Open new markets • Create barriers to entry • Reputation