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Global Brother > Environmental Activities > Efforts in Business Operations > CO2 Emission Reduction Activities


Efforts in Business Operations

CO2 Emission Reduction Activities

Activities to reduce CO2 by conserving energy

Aiming to achieve a significant reduction in CO2 emissions at manufacturing facilities and offices by FY2020

Reducing emissions of CO2 and other greenhouse gases which are main contributors to climate change is a critical challenge for modern society. The Brother Group set the target of reducing total emissions of business sites in Japan by 30% from FY1990 (November 21,1989-November 20,1990) levels, and reducing emissions of manufacturing facilities outside Japan by 20% per unit sales from FY2006 (April 1, 2006-March 31, 2007) levels, by FY2020, and has been conducting activities worldwide.

Details of the Brother Group's accomplishments in FY2010

  • * FY2010: April 1, 2010-March 31, 2011

Strengthening measures to reduce CO2 emissions at business sites around the world

The Brother Group's CO2 emissions in Japan come mainly from the electricity used by offices, while the group's CO2 emissions overseas are attributed mainly to the use of electricity and fuel at factories and offices. The Brother Group has been increasing the efficiency of air conditioning and lighting, and ensuring efficient operation of production equipment at factories, in order to reduce electricity usage and CO2 emissions.

To achieve the goals set in the Brother Group 2010 Midterm Environmental Action Plan, energy conservation diagnoses were made at seven manufacturing facilities outside Japan and one manufacturing facility in Japan in FY2007 (April 1, 2007-March 31, 2008). Based on the results, energy conservation measures were taken for power-intensive equipment, such as lighting and air conditioning equipment, compressors, chillers, clean rooms, and molding machines. Specifically, existing equipment was replaced with more efficient equipment. Great effort was also made to turn off switches whenever equipment was not in use, and to eliminate air leakage from compressors. The target of these activities was to reduce electricity consumption equivalent to about 2,500 MWh. In FY2009 (April 1, 2009-March 31, 2010), these efforts, combined with lower production due to the economic downturn, led to a significant reduction in energy consumption.

In FY2010, manufacturing facilities outside Japan continued to work on removing lights where possible, introducing LED lighting, setting up occupancy sensors, turning off lights and providing skylights instead, updating air conditioning equipment and inverter compressors, and ensuring measures to prevent air leakage. However, the recovery of the operating ratio coincided with a long heat-wave in Huanan, China where many manufacturing facilities are located. As a result, CO2 emissions increased by about 2,800 tons (decreased by about 1% per unit sales from FY2009 levels, and by about 9% from FY2006 levels).

In Japan, the Company-wide Energy Conservation Working Group was set up under the Environmental Committee to promote energy conservation activities. Overall energy conservation measures have been reviewed for power-intensive equipment including lighting and air conditioning equipment, clean rooms, compressors, and constant temperature/humidity chambers, to enhance activities.

Changes in CO2 emissions of the Brother Group
Changes in CO2 emissions of the Brother Group
  • Note: CO2 emissions are calculated based on the "Review results regarding calculation of greenhouse gas emissions" by the Ministry of the Environment, Japan. The list of emissions coefficients defined in the Order for Enforcement that came into force in September 2000 was used for calculations from FY2004 (April 1, 2004-March 31, 2005 for business sites in Japan and January 1, 2004-December 31, 2004 for facilities outside Japan) through FY2005 (April 1, 2005-March 31, 2006 for business sites in Japan and January 1, 2005-December 31, 2005 for facilities outside Japan), while the list that came into force in December 2002 was used for calculations from FY2006.

Scope of aggregation

FY2004:
Six entities of Brother Industries, Ltd. (BIL) (Headquarters, Mizuho Manufacturing Facility, Hoshizaki Manufacturing Facility, Minato Manufacturing Facility, Momozono Manufacturing Facility, and Kariya Manufacturing Facility) and seven group companies (Brother Technology (Shenzhen) Ltd., Brother Industries(Shenzhen), Ltd., Brother Industries Technology (M) Sdn. Bhd., Zhuhai Brother Industries, Co., Ltd., Taiwan Brother Industries, Ltd., Xian Typical Brother Industries, Co., Ltd.*1, and Brother Industries (U.K.) Ltd.)
FY2005:
Added one entity of BIL (Research & Development Center) to the scope of FY2004
FY2006:
Added one entity of BIL (Logistic Center) and two group companies (Brother Sewing Machine Xian Co., Ltd.*1 and Brother Sewing Machine (Shanghai) Co., Ltd.*2) to the scope of FY2005
FY2007:
Same as FY2006
FY2008:
Added one group company (Brother Industries (Vietnam) Ltd.) to the scope of FY2007
FY2009:
Same as FY2008
FY2010:
Added two group companies (Mie Brother Precision Industries, Ltd. and Brother Industries (Slovakia) s.r.o.) to the scope of FY2009
  • *: FY2004: April 1, 2004-March 31, 2005 for business sites in Japan and January 1, 2004-December 31, 2004 for facilities outside Japan , FY2005: April 1, 2005-March 31, 2006 for business sites in Japan and January 1, 2005-December 31, 2005 for facilities outside Japan , FY2006: April 1, 2006-March 31, 2007 , FY2007: April 1, 2007-March 31, 2008 , FY2008: April 1, 2008-March 31, 2009 , FY2009: April 1, 2009-March 31, 2010 , FY2010: April 1, 2010-March 31, 2011
  • *1: Brother Sewing Machine Xian Co., Ltd. merged with Xian Typical Brother Industries, Co., Ltd. in 2010. The new company is named Brother Machinery Xian Co., Ltd.
  • *2: Brother Sewing Machine (Shanghai) Co., Ltd. transferred its business to Brother Machinery Xian Co., Ltd. in 2010.

Details of BIL's accomplishments in FY2010

BIL's activities and changes in CO2 emissions

In FY2010, BIL's total energy consumption (electricity and fuel) was 18,402 tons in CO2 equivalent, up 1,532 tons (about 9.1%) from FY2009*1. In FY2009, the operating ratio decreased due to the global recession, which led to a decrease in CO2 emissions. In FY2010, the recovery in operating ratio coincided with an increased air conditioning load due to the intense heat in summer, which resulted in increased electricity consumption and CO2 emissions.

In FY2010, electricity consumption was 40,785 MWh, up 8.1% from FY2009. Fuel consumption (light oil, gasoline, LPG, and city gas) was 846 kl in crude oil equivalent, up 137 kl (about 19%) from FY2009*2. At the Kariya Manufacturing Facility, city gas consumption by gas-fueled air conditioning equipment increased due to the intense heat, and so the fuel consumption increased.

From FY2009 to FY2010, management standards were reviewed for clean rooms and constant temperature/humidity chambers and applied across the company. In FY2011 (April 1, 2011-March 31, 2012), measures taken in recent years will be reviewed and efforts will be strengthened.

The four representative associations of the electric and electronic industries*3 drew up industry-specific voluntary action plans, and set the goal of "reducing CO2 emissions per unit of real production output*4 by 35% against FY1990 levels by the year 2010 (final assessments will be based on an average over a five-year period from 2008 through 2012)" to prevent global warming. During the past three years from FY2008 (April 1, 2008-March 31, 2009), BIL succeeded in attaining a 47.7% reduction (a figure after reflecting Kyoto Credits) on average against FY1990 levels. Various measures will continue to be taken to achieve this five-year-average target.

  • *1: According to the voluntary action plans of the four representative associations, the coefficient of the averaged total power sources at the receiving end (published by the Federation of Electric Power Companies of Japan) is used to convert electricity into CO2 emissions. (FY1990: 0.417, FY2000 (April 1, 2000-March 31, 2001): 0.376, FY2001 (April 1, 2001-March 31, 2002): 0.376, FY2002 (April 1, 2002-March 31, 2003): 0.404, FY2003 (April 1, 2003-March 31, 2004): 0.433, FY2004: 0.418, FY2005: 0.423, FY2006: 0.410, FY2007: 0.453, FY2008: 0.444 (before reflecting Kyoto Credits) / 0.373 (after reflecting Kyoto Credits), FY2009: 0.412 (before reflecting Kyoto Credits) / 0.351 (after reflecting Kyoto Credits). The coefficient for FY2010 was calculated by using values in FY2009 as substitutes. The unit is t-CO2/MWh.
  • *2: For city gas, heating values published by Toho Gas Co., Ltd. (which supplies gas to Brother) are used pursuant to the Energy Conservation Law. Electric power derived from two photovoltaic power generation systems is included in electricity consumption, but is not included in CO2 emissions because the process of generating photovoltaic power does not generate CO2.
  • *3: The four associations refer to the Japan Electronics and Information Technology Industries Association, the Japan Electrical Manufacturers' Association, the Japan Business Machine and Information System Industries Association, and the Communications and Information Network Association of Japan.
  • *4: "CO2 emissions per unit of real production output" refers to CO2 emissions compensated by the corporate goods price index (electrical/electronic machinery and equipment) published by the Bank of Japan (BOJ). Real production output = Production output / domestic corporate goods price index (electrical/electronic machinery and equipment). The FY1990 levels are assumed to be 100, and FY2009 index is used for FY2010.
Changes in CO2 emissions of BIL (after reflecting Kyoto Credits)
Changes in CO2 emissions of BIL (after reflecting Kyoto Credits)
Changes in CO2 emissions of BIL (before reflecting Kyoto Credits)
Changes in CO2 emissions of BIL (before reflecting Kyoto Credits)
  FY1990 FY2005 FY2006 FY2007 FY2008 FY2009 FY2010
Electricity
(t-CO2 / year)
18,727 18,512 17,982 19,488 18,893
(15,872)
15,448
(13,161)
16,706
(14,233)
Fuel
(t-CO2 / year)
4,063 904 865 767 796 1,422 1,695
Total
(t-CO2 / year)
22,791 19,416 18,846 20,254 19,689
(16,668)
16,870
(14,582)
18,402
(15,928)
CO2 emissions
compared to FY1990 levels (FY1990 = 100)
100 85 83 89 86
(73)
74
(64)
81
(70)
Electricity - Emission coefficient
(t-CO2/ MWh)
0.417 0.423 0.410 0.453 0.444
(0.373)
0.412
(0.351)
0.412
(0.351)
Figures in parentheses represent values after reflecting Kyoto Credits.
  • Note 1: The CO2 emissions values for electricity consumption in FY2009 are different from those that were reported last year due to the revision of the conversion coefficient. The fuel conversion coefficient has also been reviewed retrospectively pursuant to the Greenhouse Gas Calculation and Reporting Manual (Ver. 3.2) released by the Ministry of the Environment, Japan.
  • Note2: Eight business sites are in the scope of aggregation for all fiscal years: Headquarters, Research & Development Center (including the former development building), as well as Mizuho Manufacturing Facility, Hoshizaki Manufacturing Facility, Minato Manufacturing Facility, Momozono Manufacturing Facility, Kariya Manufacturing Facility, and Logistic Center. Note that welfare facilities such as training centers, employee dormitories, and gymnasiums are not included.
    The Logistic Center is an entity of Brother Logitec Ltd., one of the Brother Group companies. However, fuel consumption for transportation is not included.

Efforts in logistics

The Brother Group will set management standards for reducing logistics-related CO2 emissions by FY2013 and reduce CO2 emissions by 1% per annum after FY2013.

Efforts in Japan

In Japan, the New Comprehensive Program of Logistics Policies (2009–2013) was approved at a cabinet meeting in July 2009. This program takes into consideration the trend of measures against global warming and includes targets to achieve logistics with less environmental impact. Systematic and comprehensive efforts have been made to develop logistics measures.

The Brother Group has been increasing the efficiency of sales logistics in Japan by reviewing delivery routes. In FY2006, the logistics network was rearranged to enable Brother to directly unload products shipped from manufacturing facilities outside Japan (including those in China and ASEAN countries) at the Port of Tokyo and the Port of Osaka, which are closely located to large market areas, instead of the Port of Nagoya that had been used before. Meanwhile, truck transportation was reduced and delivery distances were significantly reduced by increasing warehousing facilities. As a result, CO2 emissions were cut by about 38%. The Brother Group has successfully kept CO2 emissions low ever since.

Brother Logitec Ltd., a group company in charge of logistics operations for Brother products in Japan, considers reduction in environmental impact attributed to logistics as an important management challenge. Thus, the company has been promoting various efforts to ensure green logistics. Measures include improving the cargo loading efficiency, optimizing transportation routes by using digital tachographs to meet varying transportation quantities, and improving fuel efficiency by requiring drivers to drive economically and turn off their engines when stopped. As a result, fuel economy was improved by 5% in FY2010 compared to FY2009. Efforts have also been made to promote the use of alternative fuels. For example, cooking oil disposed of by My Friend Cafeterias (available for employees at Mizuho and Kariya Manufacturing Facilities) is now recycled into biodiesel fuel for trucks.

Sales logistics of Brother products are undertaken by a logistics company that is committed to reducing CO2 emissions and has a fleet of small hybrid trucks for delivery.

Efforts at facilities outside Japan

Brother's manufacturing facilities in China and ASEAN countries ("manufacturing facilities") produce nearly 100% of Brother products. Many of these manufacturing facilities are located in industrial parks near ports that are served by container ships, so the products can be shipped to overseas markets. The manufacturing facilities also employ containers with higher loading capacity than ordinary ones to increase the loading efficiency and reduce the number of containers required.

Sales facilities outside Japan have been stepping up efforts to track logistics-related CO2 emissions, from unloading at ports to delivery to customers, and analyze the data, so that CO2 emissions reduction measures that appropriately reflect local conditions can be implemented.

Regarding product transportation to sales facilities in the US, the unloading port was changed in FY2009 for some products arriving in the US, thereby reducing marine transportation distances, facilitating transshipping from marine to land transportation, and enabling Brother to achieve railway transportation with less environmental impact. In FY2010, the ratio of utilizing railway transportation routes was increased, which almost eliminated the use of two-ton trucks for emergency transportation. As a result, CO2 emissions were reduced by about 800 tons from FY2009.

Conventionally, products manufactured in ASEAN countries were transported to sales facilities via Brother International Singapore Pte. Ltd. In 2011, this system was replaced by direct delivery from manufacturing facilities to reduce marine transportation distances, etc.

You can watch a documentary produced by Discovery Channel, as well as the Brother Group’s activities to contribute to the global environment.


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