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"In the glass manufacturing process, energy is mainly consumed by melting sand, lime, and sodium carbonate in ovens heated to 1500 degrees by burning gas or fuel. The source of the energy consumed and its supply to the ovens are the main challenges in enabling glass producers to combat climate change effectively We have defined a concrete and ambitious action plan to combat climate change. To do so, we have identified two priority lines of action. The first is to have effective measurement and management of emissions related to our industrial activity. We also expect to take action against our greenhouse gas emissions. Our objective is to reduce the emissivity of our industrial process by 45% by 2035 and by 36% across our entire value chain (scopes 1, 2, and 3). By 2050, we want to continue our efforts and encourage innovations to align ourselves with a reduction trajectory of 2°C. That means achieving carbon neutrality in 2050." Jean-Marc Arrambourg
To challenge our emissions-reduction issues and opportunities, Saverglass called upon the Carbone 4 consultancy in 2020 to perform its Bilan Carbone® (carbon footprint assessment). As we had carried out an initial assessment in 2009, this enabled us to assess our efforts over the last ten years. This diagnostic showed that for one tonne of glass produced, one tonne of CO2 was emitted, which was a significant drop (-11%) since 2009. The assessment also enabled a detailed analysis of emission sources. Our carbon impact is mainly the result of energy consumption (59%), decarbonization (12%), purchases of inputs and services (12%), upstream and downstream logistics (9%), and other factors (8%). Emissions related to decarbonization come from the glass melting process, i.e., the liquefaction of raw materials in ovens, where they fuse at approximately 1500℃. As a result, an appropriate action plan to reduce our carbon footprint has been redefined.
Defining an ambitious low-carbon road map
Following the completion of its carbon footprint assessment (Bilan Carbone®), with the help of Carbone 4, Saverglass has implemented an approach to adjust and finalize its low carbon roadmap. We have initiated an energy management strategy to reduce CO2 emissions across the value chain, both upstream and downstream of our activity. Saverglass aims to reduce the emissions of its industrial process as a priority and influence induced emissions (scopes 1 and 2). Saverglass also aims to act on scope 3, which represents 40% of its emissions.
The main work focuses are:
Saverglass has developed a concrete and detailed action plan for each site and measured the carbon impact of each solution proposed by this plan. This has enabled the identification of process improvement levers that require accessible technologies.
To Improve air and water quality, Saverglass is committed to designing and implementing solutions to minimize its other emissions, other than CO2 (NOx, SOx, and particulate matter), to treat its effluents as efficiently as possible.
The Group has significantly reduced its other emissions over the past 20 years. Saverglass ovens are equipped with regenerators for recovering energy from fumes and the best technology available to lower the environmental impact of air releases.
When our glass decoration factory was created in Arques in 2014, a sewage treatment plant was built to treat the effluents related to the frosted finishing process. With advanced, less-polluting technology and controlled rinse water release systems, the activity significantly reduced its environmental footprint.
This system, inspired by the one developed by the Saverglass teams in the Coulommiers factory (France), was duplicated at the Acatlan de Juarez factory in Mexico (2019). All our frosted finishing sites are equipped with this innovative treatment system.
Saverglass aims to optimize the use of raw materials used in the production and decoration of bottles.
The challenge lies in achieving industrial efficiency while preserving natural resources through the controlled use of raw materials, water, and energy. Saverglass seeks to produce its bottles sustainably, by limiting the consumption of resources and the production of waste.
The Group's resource optimization approach is applied to all of its raw materials and is common to all of its sites.
The use of cullet (recycled glass from collected household glass) in the colored glass production process follows the European recycling target of 90% in 2030 and corresponds to the maturity of the recycling market in the United Arab Emirates and Mexico. It has major ecological advantages. It reduces the use of natural resources, given that cullet can replace raw materials such as sand, lime, or soda. Using cullet also saves energy as it melts faster and at a lower temperature than natural raw materials. It is a cost-effective and efficient solution for reducing emissions with no degredation of the quality of the glass produced.
In accordance with its policy of excellence and superior quality, in a market where extra-white cullet is virtually absent, the use of cullet for producing extra-white glass ranges must follow a strict process. Because cullet is made of colored recycled materials, it gives a tint to products that use it in their production. Consequently, not all glass colors accept the same proportion of cullet. The darker the color , the more cullet can be added to the manufacturing process. On the other hand, the clearer the glass, the less suitable this process becomes.
The use of bio-sourced, low-carbon materials is also part of the raw material optimization approach. Saverglass uses short supply chains.
Regarding water consumption, Saverglass has installed an effective rainwater collection system at its Feuquières site. Rainwater from the roof is directly collected in a collection basin. This has significantly reduced drinking water usage and, what's more, has provided 60% of the factory's water needs.
More broadly, Saverglass has set itself the objective of identifying good practices in 2021 that will allow it to further limit usage and then to gradually implement them throughout its sites.
As far as packaging is concerned, the Group is striving to find the most environmentally friendly solutions. Saverglass' ambition is to achieve "zero non-recycled plastic". A circular economy policy has been introduced to all sites with circuits allowing the recycling or reuse of packaging. VMF standard wooden pallets are reusable. Saverglass collects, sorts and cleans pallets from its clients, extending the life of the pallets. In tonnage, they represent 50% of recovered material. In addition, Saverglass, with the help of a supplier, recovers the inserts (plastic packaging to protect the bottles during transport) so that they can be reused in the creation of new packaging.
Saverglass has also significantly increased its use of translucent pallet covers made from recycled plastics, replacing the transparent covers that require a virgin raw material. The decrease in the weight of these pallet covers has resulted in a 15% gain in thickness for double-wrapping. This represents a saving of almost 200 tonnes of polyethylene per year. Similarly, the partial transition to single-wrapping, instead of 2 covers, has reduced thickness by 40%, which represents a saving of 100 tonnes of polyethylene per year.