Vdi zre

The VDI Centre for Resource Efficiency
A Competence Centre for SME

12th December 2012

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

An institution of the Association of German Engineers (VDI)
VDI (since 1856)
About 150.000 members 12.000 active experts

12 VDI- Societies ca. 200 new and revised
60 Technical Divisions Education VDI guidelines per year

VDI-Group

Innovation funding Technology Consulting Media Advanced Training


Institutional Context of VDI ZRE

VDI Group VDI Centre for Resource Efficiency
(VDI ZRE)
VDI e.V. VDI GmbH
■ project cooperation of the German
Ministry for the Environment (BMU)
VDI Verlag GmbH
Springer-VDI-Verlag GmbH

VDI Wissensforum
■ and the Association of German
GmbH
Engineers
VDI Technologiezentrum

■ funded in the framework of the
GmbH

VDI Zentrum National Climate Initiative of BMU.
Ressourceneffizienz
GmbH


VDI ZRE – The Mission

Science
Technology VDI ZRE

Promoting the realisation of resource-efficiency (RE) concepts in
relevant 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


Limitation of resources

Global Raw Material Usage  Raw Material Usage:
80,000,000 1979: 35 Bill. t
Bauminerale 1989: 41 Bill. t
70,000,000
Erze & Industrieminerale 1999: 49 Bill. t
Rohstoffentnahme in TSD Tonnen

60,000,000 Fossile Energieträger
2009: 68 Bill. t
2050: 120 Bill. t ?
Biomasse
50,000,000

40,000,000  Driver:
30,000,000
growth of the
population
20,000,000

10,000,000 prosperity
-

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

Limitation of resources

 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

RESOURCE EFFICIENCY (RE)
AT SMES


Resource Efficiency (RE) at SMEs
 Materials are the main cost
factor in the manufacturing Cost Structure
sector Manufacturing Sector
Other (Write-
Offs Rental
etc.)
 Personal costs are less 19%

than 20% Interest
1%

 Decreasing material Taxes Material
3% 44%
costs is the way to
 strengthen the Staff
18%
company and
External
 Support climate Suppliers
2%
protection Goods for
Resale Energy
11% 2%

Source: Federal Statistical Office Germany, 2009

Aim: increase in profit by 25%

Two Possibilities Cost Effectiveness of RE
Measures
Profit
 turnover increase by 3%
 25%
Material
 material cost decrease from Cost Other
 44% to 42,25% 44% 53%

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


Chipping out
of full block

Fabrication
out of
precast
molding
blank

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


Food industry

Source : Pfaffmann.de; own

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


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


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

New Productionlines: Energy Plus Factory

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

Quelle: VDI ZRE (2011)

Financing new technologies for resource efficiency

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 company: Advantage for the environment*:
 Paper: -1.930 KEUR/a*  Paper: -2.839 t/a
 Colour/Alcohol: -143 KEUR/a*  Colour/Alcohol: -87 t/a
 Electricity/Gas: -680 KEUR/a*  Electricity/Gas: -13 Mio. kWh/a
 more capacity  CO2-emissions: -6.347 t/a
 flexibel product design * based on the same production level
15

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 €


German Resource Efficiency Program
(Deutsches Ressourceneffizienzprogramm (ProgRess)

 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

HOW TO CONVINCE SMES TO
IMPLEMENT RE


VDI ZRE Products and Projects

Process chains Resource Checks Innovation radar Database

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


Efficiency map

RE map with information about:

 Experts specialized in RE
consultancy

 Best practice examples

 Movies about exemplary
solutions for SMEs

 Funding for RE investment


Resource Checks

Manufacturing
Metal Polymer
Basis module
processing processing

Varnishing Shape cutting Electrocoating

Foundry
Cold rolling Hot rolling
technology

Construction
Energy-
Facility
efficient
Management Lifts
Renovation
(Hospital)
(Hospital)

Online and offline versions

Process Chains
Example: Process Chain Foundry Technology

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

Web Video Magazine
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


Handbook VDI Guidelines for RE

1 Methodische Grundlagen der Bewertung
von Ressourceneffizienz

VDI VDI VDI VDI VDI
4597 4598 4599 4600 4601

© Verein Deutscher Ingenieure (2011)
Rahmen RE in KRA KEA UI
KMU

2 Anwendung
VDI-Branchenleitfäden Produktionsintegrierter
Kennzahlen Umweltschutz

Branche Branche VDI VDI
Branche Branche 3 … VDI VDI
4075-3 4075-x
1 2 4075-1 4075-2

existing
3 Richtlinien zu Einzelfragen
in progress
VDI VDI VDI VDI VDI VDI VDI
2243 2343 4070 4661 … … … planned

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

Qualification course Resource Efficiency (RE)

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)
www.qualifizierung-re.de
 Practical application of theory
 Plant tours
 Guided expert dialogue


Campaign „Competitive edge by Resource efficiency“
 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


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

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

VDI Zentrum Ressourceneffizienz GmbH
Johannisstr. 5-6
D-10117 Berlin
+49 30 27 59 506-0
www.vdi-zre.de
info@vdi-zre.de


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