A Design Methodology to save the Environment

Visalam Ramakrishnan Pune Institute of Engineering & Technology

Pune- 411005 2004-2005 !eminar Re"ort on

Eco-Design (A Design Methodology to save the Environment)

By

Visalam Ramakrishnan

E#amination $o% &2010''(

Roll $o% 4)1'

*n+er the gui+ance of Prof% R%&% Ingle

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Certificate

This is to certify that the seminar entitle+ ,ECO-DESIGN (A Design Meth ! l gy t sa"e the En"ir nment#$ su-mitte+ -y Visalam Ramakrishnan% E&aminati n N ' B()*)++, for the "artial fulfillment for the a.ar+ of +egree of &%E% /0echanical Engineering1 of uni2ersity of Pune3 is a""ro2e+%

Prof% !%R% 4a5ale

6ea+ of the 7e"artment 7e"artment of 0echanical Engineering Pune Institute of Engineering & Technology Pune - 411005

Prof% R%&% Ingle

8ui+e 7e"artment of 0echanical Engineering Pune Institute of Engineering & Technology Pune - 411005

E#aminer

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Ackn -le!gement

I .oul+ like to "lace on recor+ my sincere thanks to .r f' R'B' Ingle3 7e"artment of 0echanical Engineering3 Pune Institute of Engineering an+ Technology3 for his gui+ance an+ a+2ice throughout% 0y thanks are +ue to my father3 Dr' /' Ramakrishnan3 .ho intro+uce+ the su-5ect of Eco-7esign to me an+ for "ro2i+ing rea+ing an+ reference materials an+ to my mother3 Mrs' Sheila Ramakrishnan3 .ho su""orte+ me throughout for the success of this "ro5ect%

Visalam Ramakrishnan

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Preface

9e are li2ing in a .orl+ .ith gro.ing "o"ulations an+ increasing consum"tion of natural resources% :ur lifestyles are likely to lea+ to irre"ara-le +amage to the "hysical en2ironment in the near future% :ne estimate from the 9orl+ &ank in+icates that if .e li2e the .ay .e li2e to+ay3 .e may nee+ four earths to satisfy the human nee+s -y the year 2100% It is therefore necessary to inter2ene in the "rocess of consum"tion of resources to im"ro2e the .ays these resources are use+% 7esigners "lay an im"ortant role in this inter2ention% They can +esign "ro+ucts that consume less materials an+ nee+ less energy to o"erate to gi2e the nee+e+ ser2ices% In this short "resentation on Eco-7esign I shall attem"t to ca"ture the salient features of the Eco-7esign metho+ as it is "ractice+ to+ay% I am sure that this "resentation .ill stimulate at least a fe. of my frien+s to ,think +ifferently; an+ to contri-ute to "reser2e the earth for the future generations%

Visalam Ramakrishnan

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C ntents
!u-5ect ckno.le+gment Preface <ontents En2ironmental Im"acts of <onsumer Pro+ucts En2ironmentally <onscious 7esign /Eco-7esign1 Eco-7esign 0etho+s E#isting Practices in Eco-7esign 1% 7esign for 0ass Re+uction 1%1% 7esign for !ource Re+uction 1%2% 7esign for 0ultifunctional Pro+ucts 2% 7esign for Energy Re+uction 2%1% Re+uce Energy in Pro+uction 2%2% Re+uce 7e2ice Po.er <onsum"tion 2%)% Re+uce Trans"ortation Energy <onsum"tion 2%4% *se of Rene.a-le Energy )% Re+uction of 6a>ar+ous !u-stances )%1% Re+uce Pro+uction Releases )%2% 2oi+ :>one 7e"leting <hemicals )%)% *se 9ater--ase+ technology )%4% ssure Pro+uct &io-+egra+a-ility )%5% ssure 9aste 7is"osa-ility )%(% 2oi+ &anne+ !u-stances 4% 7esign for Recycla-ility 4%1% 7esign for 0aterial Recycling 4%2% 7esign for <om"onent Reco2ery 4%)% 7esign for 7isassem-ly 4%)%1% @acilitate ccess to <om"onents 4%)%2% !im"lify <om"onent Interfaces 4%)%)% 7esign for !im"licity 4%)%4% 7esign for !e"ara-ililty 4%)%5% 2oi+ 0aterial <ontaminants 4%)%(% 7esign for 9aste Reco2ery an+ Reuse 4%)%=% 7esign for 9aste Incineration 4%)%'% 7esign for Packaging Reco2ery 5% Packaging 0ass Re+uction (% 7esign for Pro+uct Aife !ome Eco-7esign 8ui+elines E2aluation of En2ironmental Im"acts of Pro+ucts an+ Processes @ast @i2e Eco-Estimator En2ironmental 9eight <alculation Eco-In+icator /Eco!can1 &enefits of Eco-7esign ty"ical <ase !tu+y B @ree Po.er Ra+io3 Phili"s In+ia <onclu+ing Remarks Page ( of 22 Page $o% 2 ) 4 5 5 5 ( ( ( ( = = = = ' ' ' ' ' ' ' ' ? ? ? 10 10 10 11 11 11 12 12 12 12 12 1) 1) 14 15 15 15 1( 1= 1?

References

20

Ec -Design 0 a !esign meth ! l gy t sa"e the en"ir nment

En"ir nmental Im1acts f C ns2mer .r !2cts3 <onsumer "ro+ucts cause en2ironmental im"acts throughout their life cycle3 from manufacturing3 through sales an+ marketing3 use an+ finally +is"osal of the "ro+uct% @or e#am"le3 +uring the manufacturing "hase of the "ro+uct3 these im"acts are relate+ to /a1 the use of resources3 such as ra. materials3 energy3 .ater /-1 air3 .ater an+ soil "ollution3 /c1 generation of .aste an+ /+1 health effect on em"loyees etc% 7uring the ,sales an+ marketing; "hase the im"acts are +ue to the generation of "ackaging .aste an+ the use of fuels an+ the "ollution cause+ -y trans"ortation of "ro+ucts% The ma5or en2ironmental im"act +uring the use of the "ro+uct /es"ecially an electronic C electrical "ro+uct1 is the consum"tion of energy3 lea+ing in+irectly to greenhouse gas emissions an+ generation of .aste /-attery1% There is also a likelihoo+ of a health im"act on the user .ith certain ty"es of "ro+ucts% fter the en+ of life /E:A1 of the "ro+uct3 the "ro+uct -ecomes a soli+ .aste if it is not recycle+3 reuse+3 remanufacture+3 re"aire+ or re-circulate+% The soli+ .aste3 .hich can also -e ha>ar+ous3 is +is"ose+ off either -y lan+-filling or -y incineration% The en2ironmental im"acts at this "hase inclu+e /a1 air3 .ater an+ soil "ollution3 /-1 health effects on the society an+ /c1 loss of amenity 2alue% En"ir nmentally C nsci 2s Design (Ec -Design#3 Eco-7esign /En2ironmentally <onscious 7esign1 is a +esign conce"t .hich takes into account the en2ironmental im"act of the "ro+uct +uring the .hole life-cycle of the "ro+uct3 ena-ling the +esigner to re+uce the total en2ironmental im"act of the "ro+uct throughout its life-cycle% T.o facts a-out Eco-7esign are im"ortant to a""reciate at this stageD /a1 Eco-7esign is a com"osite of many +esign "rinci"les - Eco-7esign encom"asses many micro-conce"ts such as /i1 +esign for recycle3 reuse an+ re-manufacture3 /ii1 +esign for +isassem-ly3 /iii1 +esign for +is"osal3 /i21 +esign for energy efficiency3 /21 +esign for .aste re+uction3 /2i1 +esign for material efficiency3 /2ii1 +esign for risk-re+uction3 /2iii1 +esign for acci+ent "re2ention etc%3 an+ /-1 Eco-7esign is a "art of the Pro+uct <reation Process3 i%e%3 it has to -e integrate+ into the +esign "rocess B Eco-7esign "rinci"les ha2e to -e incor"orate+ at +ifferent stages of the P<P as sho.n% Ec -Design Meth !s ll Eco-7esign metho+s focus on one or more of the follo.ing ,green focal areas;D 0ass Re+uction 6a>ar+ous su-stances re+uction Energy <onsum"tion Recycla-ility Packaging 0ass Page = of 22

E#tention of the Aife of the "ro+uct

0ass Re+uction meansD /i1 less use of natural resources /ii1 less use of "rocessing chemicalsCsu-stances3 /iii1 less "ollution +uring "rocessing3 /i21 less .aste /inclu+ing E:A13 /21 less Packaging3 /2i1 less trans"ortation "ollution etc% Energy efficiency meansD /i1 less greenhouse gas /car-on +io#i+e1 emissions3 /ii1 less use of -attery an+ /iii1 less .aste /-attery1 Re+uctionCElimination of 6a>ar+ous su-stancesD Aess health effects +uring the manufacturing3 use an+ +is"osal of "ro+ucts Recycla-ility meansD /i1 e#ten+e+ material use3 /ii1 e#ten+e+ com"onentC"art use3 /iii1 re+uction in +e"letion of resources3 /i21 re+uction in E:A .aste3 /2i1 re+uction in "ollution Packaging mass re+uction results inD /i1 re+uce+ use of resources3 /ii1 re+uce+ trans"ortation "ollution an+ /iii1 re+uce+ .aste generation E#ten+e+ life of the "ro+uct means the use of scarce resources for a longer time "erio+3 i%e% im"ro2e+ resource "ro+ucti2ity /-etter eco-efficiency1 E&isting .ractices in Ec -Design *' Design f r Mass Re!2cti n 1%1% Design f r s 2rce re!2cti n D

!ource re+uction is routinely "ractice+ as the most +esira-le alternati2e in the "ollution "re2ention hierarchy /Pre2ention is -etter than cure1% Re+ucing the mass of a "ro+uct is the surest an+ most +irect .ay to achie2e .aste re+uction3 an+ usually results in lo.er life-cycle costs as .ell% In many in+ustries3 such as foo+ an+ -e2erages3 the mass of the "ro+uct itself is infle#i-le3 an+ ingenious metho+s must -e foun+ to re+uce the mass of containers an+ "ackaging% The follo.ing is a list of gui+elines re"resenting the most common source re+uction "racticesD *'(' Re+uce the "ro+uctEs "hysical +imensions /miniaturi>ation1 !"ecify lighter-.eight materials as su-stitutes /e%g% Plastics i"o metal1 7esign thinner enclosures .ith e#isting materials Increase the concentration in liFui+ "ro+ucts /7ilution at use1 Re+uce the mass of key com"onents Re+uce the .eight or com"le#ity of "ackaging *se electronic +ocumentation instea+ of "a"er Design f r m2ltif2ncti nal 1r !2cts 3

Pro+ucts .hich ha2e multi"le uses are -y nature eco-efficient3 in that the same amount of material achie2es a higher le2el of functionality% The greater the "ro"ortion of time +uring

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a "ro+uct life that the "ro+uct is actually in use3 the greater the ratio of 2alue +eli2ere+ to resources consume+% There are essentially t.o ty"es of multi"le functionalityD (' ('*' Parallel functions3 in .hich the same "ro+uct may simultaneously ser2e se2eral +ifferent "ur"oses / e%g% a 2i+eo camera that also ser2es as a "lay-ack +e2ice1 !eFuential functions3 in .hich a "ro+uct is retire+ from its "rimary use an+ then a""lie+ to a secon+ary an+ tertiary use% Energy Re!2cti n3 Re!2ce energy 2se in 1r !2cti n 3

Energy conser2ation is one of the most attracti2e a""roaches to "ollution "re2ention3 -ecause it is -oth easy to im"lement an+ results in +irect cost sa2ings% E2ery kilo.atthour of electricity not use+ "re2ents the emission of a""ro#imately '00 g of <:2 3 ( g of !:2 an+ 2 g of $:#% ('(' Re!2ce !e"ice 1 -er c ns2m1ti n3

Re+uce+ "o.er consum"tion in com"uters an+ "eri"herals is accom"lishe+ -y means of "o.er management features that "o.er +o.n a unit .hen it has not -een use+ for some length of time% !uch features ha2e alrea+y -ecome stan+ar+ eFui"ment on la"to"s% In other ty"es of "ro+ucts3 energy efficiency is achie2e+ through +e2elo"ing more efficient motors an+ re+ucing the energy loa+% @or e#am"le3 "o.er use in refrigerators has +ecline+ -y )0G 3 encourage+ in "art -y the ,+eman+-si+e management; energy conser2ation efforts of electric utility% ('4' Re!2ce trans1 rtati n energy c ns2m1ti n3

n often o2erlooke+ as"ect of energy use is the +istri-ution chain of "ro+ucts3 inclu+ing shi"ments from com"onent 2en+ors to manufacturers or assem-lers3 from manufacuteres to +istri-ution centers or retail stores an+ from these interme+iate "oints to customers% It is not uncommon for a "ro+uct to go through half a +o>en shi"ment stages -y 2arious mo+es -efore arri2ing at its ultimate +estination% Each leg of such a 5ourney may entail significant cost as .ell as energy consum"tionH the most e#treme case is shi""ing a missing "art -y courier to meet a +eli2ery +ea+line% lthough the "lanning of +istri-ution logistics is not normally consi+ere+ a +esign acti2ity3 it is certainly an im"ortant "art of integrate+ "ro+uct +e2elo"ment% In+ee+3 there are certain as"ects of a "ro+uctEs "hysical +esign3 inclu+ing sha"e3 thermal tolerance3 an+ 2i-ration tolerance3 that limit the a2aila-le +istri-ution efficiency D Re+uce the total trans"ortation +istance for a "ro+uct or its com"onents B e%g% -y shi""ing mo+ules that are outsource+ +irectly from the su""lier to the final customer% Re+uce the trans"ortation urgency -y allo.ing sufficient lea+ time to utili>e lo.cost -ulk shi"ment% Re+uce the shi""ing 2olume reFuire+ -y re+esigning the "ro+uct geometry3 "ackaging 2olume3 or stacking configuration so that less s"ace is .aste+% Re+uce Page ? of 22

s"ecial tem"erature reFuirements or other shi""ing constraints that consume energy ('5' 6se f rene-a7le energy3

:ne a""roach to sustaina-le +e2elo"ment is su-stitution of rene.a-le energy resources such as solar "o.er an+ hy+ro"o.er for nonrene.a-le resources such as fossil fuels% Resources are consi+ere+ rene.a-le if the rate at .hich they are re"lenishe+ is sufficient to com"ensate for their +e"letion% 6o.e2er3 life-cycle analyses ha2e in+icate+ that the full im"act of "o.er generation -y some ,rene.a-le; forms3 such as solar3 may -e eFui2alent to those of nonrene.a-le formsif one takes into account the ca"ital- an+ la-orintensi2e acti2ities reFuire+ to construct the necessary eFui"ment an+ facilities% 4' 4'* ' Re!2cti n f 8a9ar! 2s S27stances Re!2ce 1r !2cti n releases 3

7esigning ,cleaner; "rocesses is a more effecti2e means of "ollution "re2ention than merely retrofitting e#isting "rocesses% 4'(' A" i! O9 ne !e1leting chemicals 3

The .orl+.i+e -an on <@<Es com-ine+ .ith <@< la-elling rules3 ha2e all -ut eliminate+ ne. uses of <@<Es% 6o.e2er3 su-stitute chemicals such as "erflurocar-ons ha2e similar "ro"erties3 an+ may -e foun+ to -e cul"rits in o>one +e"letion% 9hile3 there is much scientific contro2ersy o2er the 2ali+ity of such claims3 manufacturers shoul+ carefully consi+er their "rocess +esign choices an+ seek .ays to eliminate chemicals% 4'4' 6se -ater-7ase! techn l gies 3

The su-stitution of aFueous sol2ents for cleaning of "arts an+ other in+ustrial "rocesses has -ecome .i+es"rea+% Through -etter control of mechanical an+ hy+raulic factors3 aFueous cleaning can -e as effecti2e as tra+itional metho+s that use more ha>ar+ous chlorinate+ sol2ents% 4'5' Ass2re 1r !2ct 7i !egra!a7ility D

@ormulation of "ro+ucts .hich +egra+e un+er ty"ical +is"osal con+itions is a common a""roach in cases .here recycling is not feasi-le% 4':' Ass2re -aste !is1 sa7ility 3

<ertain .aste materials cannot -e economically reco2ere+ an+ re"rocesse+% In these cases it is im"ortant that their "hysical form an+ ha>ar+ous constituents -e controlle+ to assure safe an+ efficient +is"osal 4',' A" i! 7anne! s27stances3

:ne of the most im"ortant as"ects of eco-+esign is to eliminate the use of su-stances like ca+mium /-anne+ in Euro"e13 mercury3 lea+ /-anne+ in the *! 13 "oly-romo-i"henyls3 Page 10 of 22

"oly-romo-i"henylethers3 "olychloro-i"henyls3 /all these halogenate+ com"oun+s ha2e -een -anne+ un+er P:P con2ention13 as-estos /-anne+ in the *! 13 chromium /2i1 an+ other hea2y metals% In In+ia3 the use of a>o-+yes has -een -anne+% 5' 5'* Design f r Recycling Design f r material rec "ery 3

To -e reco2era-le .ith "ositi2e economic 2alue3 materials nee+ to -e as close as "ossi-le to the state of manufacturing fee+stock% 0aterial homogeneity3 "urity an+ re"rocessa-ility are im"ortant consi+erations in +etermining their reco2ery 2alue% 0ost com"osite materials cannot -e se"arate+ into their sim"ler an+ "urer constituent materials an+ therefore are not recycla-le e#ce"t for .aste incineration% Recycla-le materials inclu+e thermo"lastics3 engineering "lastics3 metals an+ glass% s recycling technologies an+ materials science im"ro2e3 .e are reaching a "oint .here recycla-le materials can -e foun+ for 2irtually any a""lication% @actors to -e consi+ere+ .hile selecting material areD 5'( The economic attracti2eness of recycling the material an+ the e#istence of en+-use markets% The 2olume3 concentration an+ "urity of the recycle+ material% The e#istence of recycling an+ se"aration technologies an+ an a+eFuate recycling infrastructure% Design f r c m1 nent rec "ery 3

In case .here "ro+uct technology -ecomes o-solete ra"i+ly3 entire systems can -e refur-ishe+ an+ resol+% @or e#am"le3 there are thri2ing secon+ary markets for automo-iles an+ "ersonal com"uters% If the entire system is either not o"era-le or not marketa-le3 the "riority is to +isassem-le it an+ try to reco2er 2alua-le com"onents% lthough most sal2age+ com"onents are resol+ to secon+ary markets3 to the e#tent that refur-ishe+ com"onents can -e remanufacture+ into ne. "ro+ucts this .ill contri-ute to achie2ement of closed-loop recycling. 7esign consi+erations are im"ortant in +etermining the en+-of-life 2alue of 2arious com"onents% Pro+uct +e2elo"ers can increase this 2alue in a num-er of .aysD 7esigning com"onents that are reusa-le for "ur"oses of close+-loo" manufacturing% 7esigning com"onents that are reusa-le for secon+ary a""lications +ue to their generic functionality3 fle#i-ility or "rogramma-ility% @acilitating the non+estructi2e remo2al of the com"onent B for e#am"le3 surfacemounte+ chi"s are +ifficult to reco2er -ecause their tiny lea+s -ecome -ent% 7esigning the com"onent in a .ay that s"ee+s the +iagnosis an+ refur-ishment

5'4' Design f r !isassem7ly 4%)%1% @acilitate access to com"onents D Page 11 of 22

The "ur"ose of +esign for +isassem-ly is to assure that a "ro+uct system can -e +isassem-le+ at minimum cost an+ effort% This im"ortant "rereFuisite to other en+-of-life consi+erations such as com"onent se"ara-ility an+ recycla-ility% If you cant get access to a com"onent3 no matter ho. 2alua-le3 then you cannot reco2er it% The e#tent to .hich a unit3 mo+ule3 assem-ly or com"onent shoul+ -e +isassem-le+ +e"en+s not only on the costs of +isassem-ly3 se"aration3 ins"ection3 sorting an+ refur-ishment3 -ut also on its reuse3 resale or sal2age 2alues% @or e#am"le3 it may not -e cost-effecti2e to +isassem-le "ro+ucts that contain many +ifferent3 +ifficult to i+entify materials% !imilarly3 if com"onents3 assem-lies an+ mo+ules cannot -e reuse+ or refur-ishe+3 an+ if they contain largely nonrecycla-le materials3 little +isassem-ly is .arrante+% t any stage of +isassem-ly3 the a-ility to remo2e a com"onent or "art is a key consi+eration% @or e#am"le3 "arts that are em-e++e+ in an incom"ati-le material3 it makes it +ifficult to recycle the assem-ly% If the +esign +oes not allo. for easily se"ara-le "arts3 then em-e++e+ "arts shoul+ -e constructe+ of recycla-le an+ com"ati-le materials% 4%)%2% !im"lify com"onents interfacesD 7isassem-ly in2ol2es the seFuential remo2al of com"onents an+ therefore the technologies use+ for the interfaces +irectly influence the ease of +isassem-ly% The follo.ing gui+elines .ill contri-ute to s"ee+ing u" +isassem-ly "rocess an+ reco2ering a larger "ro"ortion of system com"onentsD 2oi+ s"rings3 "ulleys an+ harnesses .hich com"licate the +isassem-ly "rocess 0inimi>e the use of a+hesi2es an+ .el+s -et.een com"onents .hich may -e se"arate+ or -et.een incom"ati-le materials% +hesi2es intro+uce contaminants3 can +etract from Fuality +ue to the "otential for -on+ failure3 an+ increase the costs associate+ .ith +isassem-ly% If a+hesi2es are reFuire+3 try to use a+hesi2es that are com"ati-le .ith the 5oine+ materials *se sna" fits to 5oin com"onents .here "ossi-le% !na" fit in2ol2e an un+ercut on one "art engaging a mol+e+ li" on a mating "art to retain an assem-ly% !na" fits are relati2ely ine#"ensi2e to manufacture3 an+ ha2e attracti2e mechanical "ro"erties *se alternati2e -on+ing metho+s such as sol2ent -on+ing or ultrasonic -on+ing% !uch metho+s may -e acce"ta-le for -on+ing "arts ma+e from the same material an+ .hich .ill not -e se"arate+ at en+ of life !"ring cli"s or s"ee+ cli"s can -e an ine#"ensi2e an+ effecti2e .ay of 5oining "arts an+ materials% They "ermit easy assem-ly an+ +isassem-ly3 an+ +o not intro+uce contaminants

4%)%)% 7esign for sim"licityD

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7esign elegance has long -een a +esira-le attri-ute of "ro+ucts% 9ith the a+2ent of en2ironmental consciousness3 elegance in the form of sim"licity has acFuire+ a strong a++e+ moti2ation% !im"licity usually lea+s to lo.er manufacturing cost3 lo.er material mass3 greater +ura-ility an+ easier +isassem-ly for "ur"oses of maintenance or asset reco2ery% There are se2eral .ays in .hich +esigners can try to achie2e greater sim"licityD Re+ucing the com"le#ity of the "ro+uct enclosures an+ assem-lies in terms of their geometric an+ s"atial +esign3 as .ell as the com"le#ity of their functional o"eration Re+ucing the num-er of +istinct "arts that are incor"orate+ into a +esignH this is the .ell kno.n techniFue in the fiel+ of +esign for manufacture an+ assem-ly 7esigning multifunctional "arts that ser2e a 2ariety of "ur"oses3 e%g%3 using a single ty"e of fastener for all assem-lies *tili>ing common "arts in a num-er of +ifferent +esigns3 re"resenting either +ifferent mo+els in a "ro+uct family or successi2e "ro+uct generations

4%)%4% 7esign for se"ara-ilityD !e"ara-ility of incom"ati-le materials an+ com"onents is an im"ortant characteristic in +etermining the o2erall recycla-ility of a +esign% E2en after +isassem-ly is com"lete3 materials nee+ to -e sorte+ into +ifferent categories for "ur"oses of recycling% key strategy for se"ara-ility3 an+ an ine#"ensi2e one3 is to facilitate i+entification of materials -y means of co+ing or marking% @or e#am"le3 the International :rgani>ation for !tan+ar+i>ation /I!:1 has +e2elo"e+ a generic i+entification an+ marking stan+ar+3 I!: 114(?3 for "lastic "ro+ucts% The goal of the stan+ar+ is to hel" i+entify "lastic "ro+ucts for the "ur"oses of han+ling3 .aste reco2ery or +is"osal 4%)%5% 2oi+ material contaminantsD There are a num-er of "otential contaminants that cannot easily -e se"arate+ from "ro+uct or "ackaging materials% E#am"les inclu+e a+hesi2es3 inks3 "aints3 "igments3 sam"les an+ la-els% 0any manufacturers ha2e -egun to use integral finishes instea+ of "ainte+ finishes% This has a+2antages in terms of -oth lo.er manufacturing cost an+ recycla-ility% 9hile +iscrete la-els are sometimes necessary3 integral la-els are "refera-le from an en2ironmental "oint of 2ie.% 7iscrete la-els often ma+e of incom"ati-le materials an+ intro+uce contaminants% They must -e com"letely remo2e+ -efore a "art can -e recycle+3 .hich increases the material se"aration cost% lternati2es to +iscrete la-els inclu+e mol+e+-in or em-osse+ la-els% If +iscrete la-els are necessary3 it is -est to a2oi+ "rinte+ la-els3 or to use com"ati-le inks% 7iscrete la-els can -e manufacture+ from the same materialas the -ase "art an+ attach .ithout use of a+hesi2es 4%)%(% 7esign for .aste reco2ery an+ reuseD

Page 1) of 22

9aste is "ro+uce+ at e2ery "oint in the life cycle of a "ro+uct% The actual .aste associate+ .ith the +iscar+e+ "ro+uct at en+ of life may -e only a fraction of the .aste generate+ -y the manufacture3 use3 an+ +is"osal of a "ro+uct% $e. en2ironmental technologies are -eing +e2elo"e+ that can reco2er useful materials from .astes% &y consi+ering such o""ortunities +uring the "ro+uct +esign3 engineers are a-le to ma#imi>e the 2alue e#tracte+ from .aste materials 4%)%=% 7esign for .aste incinerationD

The lo.est form of material reco2ery is con2erting .aste to energy3 usually -y incineration% 6o.e2er3 this is still "refera-le to lan+-filling from an en2ironmental "ers"ecti2e3 an+ in some cases from the cost "ers"ecti2e as .ell% 9aste-to-energy facilities can -e installe+ in many "arts of the country that incinerate munici"al soli+ .aste3 -iomass /e%g3 .oo+ chi"s13 or other .astes /e3g% automoti2e tyres3 railroa+ ties3 utility "oles1 to generate steam an+ "ro+uce energy in the form of electricity% 4%)%'% 7esign for "ackaging reco2eryD In the fiel+ of in+ustrial "ackaging3 great stri+es ha2e -een ma+e in +e2elo"ing metho+s an+ technologies for the reco2ery3 recycling an+ reuse of "ackaging material :' .ackaging Mass Re!2cti n

Packaging has three main functions3 2i>%3 /a1 Packaging "rotects the "ro+uct from +amage +uring trans"ortation3 han+ling an+ storage from the time the "ro+uct lea2es the manufacturing unit till it reaches the customer3 /-1 Packaging attracts the customer to the "ro+ucts /es"ecially for consumer "ro+ucts1 an+ /c1 Packaging gi2es information a-out the "ro+uct an+ its han+ling% 0aterial resources use+ for Packaging are use+ for a short "erio+ of the life cycle of the "ro+uct3 that is from the time the "ro+uct lea2es the factory till it reaches the customer% fter the customer un"acks the "ro+uct3 the "ackaging -ecomes a .aste% 6ence it is +esira-le to +esign the "ackaging in such a .ay to im"ro2e its resource "ro+ucti2ityH one .ay of +oing this is to re+uce the mass .ithout com"romising on "ackaging Fuality% The other .ay of im"ro2ing "ackaging resource "ro+ucti2ity is to +esign "ackaging in such a .ay that the use+ "ackaging can -e utili>e+ for other "ur"oses% Packaging +esign may consi+er eliminating use of materials such as Poly2inylchlori+e3 "olyurethane foam3 "olystyrene foam3 laminate+ "lastics etc% ,' Design f r .r !2ct life 3 The longer the life of a "ro+uct3 the more eco-efficient it is3 since the same amount of material +eli2ers a larger amount of economic 2alue% To the e#tent that manufacturers can maintain "rofita-ility3 they may -e .illing to increase "ro+uct life3 charge a "remium an+ acce"t a +ro" in sales 2olume% @rom a consumer "oint of 2ie.3 longer life "ro+ucts are generally more +esira-le -ecause of con2enience an+ cost sa2ings% "art from the life e#tension for the "ro+uct as a .hole3 another .ay to achie2e longe2ity is to e#ten+ the life of "ro+uct com"onents% There are at least t.o .ays to accom"lish this D Page 14 of 22

7esign u"gra+ea-le com"onents% 7esign a reusa-le "latform%

S me Ec -Design G2i!elines a1 !"ecify recycle+ materialsD n im"ortant as"ect of sustaina-le +e2elo"ment is the conser2ation of nonrene.a-le resources% 0any firms ha2e -egun to encourage the use of more , en2ironmentally conscious; materials that ha2e significant le2els /25 to 100 G1 of recycle+ content% This is feasi-le to the e#tent that su-stitution of recycle+ materials .ith "otential im"urities is cost effecti2e an+ +oes not com"romise the Fuality of the final "ro+uct% 0etals are easily recycle+3 -ecause they can -e "urifie+ in a molten state% 6o.e2er3 for engineering thermo"lastics3 the thermomechanical "ro"erties an+ color tolerances associate+ .ith recycle+ resins may -e significantly com"romise+% :ne a""roach is to utili>e 2irgin materials only for critical com"onents an+ recycle+ materials for less +eman+ing a""lications such as -ase assem-lies -1 !"ecify rene.a-le materialsD Instea+ of recycling nonrene.a-le materials3 an alternati2e a""roach to sustaina-le +e2elo"ment is su-stitution of rene.a-le materials% 0aterials are consi+ere+ rene.a-le if the rates at .hich they are re"lenishe+ are sufficient to com"ensate for their +e"letion% @or e#am"le3 materials +e2elo"e+ through agriculture are rene.a-le% Pro+ucts that use rene.a-le materials inclu+e soy inks an+ .oo+s "ro+ucts c1 *se remanufacture+ com"onentsD Pro+ucts manufacture+ .ith refur-ishe+ com"onents can "otentially ha2e the same le2el of Fuality as one manufacture+ .ith -ran+ ne. com"onents s ela-orate+ a-o2e3 En2ironmental <onscious Pro+uct 7esign or Eco+esign is largely a matter of common sense% It "romotes the efficient use of natural resources -y "ro2i+ing the ser2ice of the "ro+uct .ith lo.est "ossi-le en2ironmental im"act% E"al2ati n f En"ir nmental Im1acts f .r !2cts an! .r cesses There are Fuite a fe. metho+s a2aila-le for assessing en2ironmental foot-"rint of a "ro+uct or a "rocess% :f these the most fun+amental is the ,Aife <ycle nalysis; /A< 1% A< reFuires you to e#ten+ your hori>ons from your imme+iate -usiness to consi+er .here your ra. materials come from an+ the +is"osal of your "ro+ucts an+ the links -et.een them3 .ith the im"lication that you -ear some res"onsi-ility for any u"stream or +o.nstream im"acts% This challenging techniFue in2ol2es the collection an+ analysis of in"ut an+ out"ut for all stages of the "ro+uct life cycle% 9hat shoul+ a life cycle "ers"ecti2e inclu+e I 9hat u"stream o"erations /e#traction3 culture3 se"aration3 etc1 are necessary to "ro2i+e ra. materials to the first ma5or manufacturing unitI Page 15 of 22

9hat manufacturing ste"s are nee+e+ -efore the "ro+uct is rea+y for shi"mentI 9hich +o.nstream o"erations an+ +istri-utions lie -et.een your com"anyEs o"eration an+ the en+ userI 9hich function +oes the final "ro+uct "erform .hile it lasts .ith the consumerI 9hat are the re2alori>ation o"tions that are -e consi+ere+ at the en+ of the "ro+uctEs ser2ice lifeI 9hat are the +is"osal o"tions of the ultimate .aste streamsI

A< is mostly carrie+ out in Research Institutions an+ *ni2ersitiesH in the In+ustrial +esign centers conce"ts of A< are follo.e+ through sim"lifie+ metho+s such asD @ast fi2e Eco-estimator En2ironmental .eight calculations Eco-In+icator metho+s

;ast ;i"e3 @ast fi2e is a ty"ical a.areness raiser an+ this lo. threshol+ tool can -e use+ to share o"inions3 initiate Fuick strategic +iscussions an+ "ro"ose fun+amental changes% In this case no calculations are reFuire+ an+ can -e carrie+ out in a-out an hourJs time% It is -est suite+ for managerial -rainstorming of the ne. "ro+uct +e2elo"ment% reference "ro+uct is reFuire+ for the analysis an+ ma5or +ifferences for more than one feature or conce"t can -e com"are+% This tools contains a Fuestionnaire .ith KesC$o entries along fi2e "arameters3 2i>% Energy 7oes the "ro"ose+ +esign reFuire less energy consum"tion than the reference "ro+uctI <onsi+er manufacturing3 trans"ortation3 "ro+uct usage /normal an+ stan+-y1 an+ +is"osal% Recycla-ility

Is the "ro"ose+ +esign more recycla-le than the reference "ro+uctI <onsi+er facts like - .hether larger com"onents can -e easily se"arate+ into mono materials3 se"aration "ossi-ilities of non-com"ati-le materials% 6a>ar+ous 9aste

7oes the "ro"ose+ +esign contain an+Cor "ro+uce less chemical .aste than the reference alternati2eI <onsi+er .hether any restricte+ materials are use+% 7ura-ility3 Re"aira-ility & Preciousness

7oes the "ro"ose+ +esign ha2e -etter +ura-ility3 re"aira-ility or affection le2el than the reference "ro+uctI Page 1( of 22

 <onsi+er the life of the "ro+uct3 ease of re"air an+ ease of u"gra+e% 7oes the "ro+uct Fualify as a classic "ro+uctI lternati2e .ays to "ro2i+e ser2ices re there .ays to "ro2i+e the ser2ice that ha2e lo.er ecological loa+sI <onsi+er .hether there are techniFues that reFuire much less energy or material3 -ut "ro2i+e this ser2ice at the same le2el of Fuality%

Ec -Estimat r3 The Eco-Estimator is a structure+ sim"le Fuantitati2e Fuestionnaire3 .hich is in "rinci"le self-e#"lanatory an+ +oes not reFuire a se"arate +ata-ase% This tool "ro2es to -e 2ery suita-le in -rainstorming +iscussions to su""ort the initial +esign +irection -y means of the resulting en2ironmental "riority o"tions% It can -e carrie+ out in a cou"le of hours% En"ir nmental -eight calc2lati n3 This is a +etaile+ a""roach that in2ol2es the calculation of en2ironmental .eight of each an+ e2ery com"onent of the "ro+uct% This is an a-solute analysis an+ not a com"arati2e one% In this +ifferent ratings are gi2en to ra. materials3 manufacturing "rocesses an+ surface finish +e"en+ing on their en2ironmental im"acts% These factors are use+ to arri2e at an en2ironmental ratio an+ "ro+ucts a-o2e a "re-agree+ num-er shoul+ -e re.orke+ u"on to kee" the 2alue -elo. this num-er% This .eight calculation is -ase+ on an e#tensi2e +ata-ase of com"arati2ely rate+ materials3 "rocesses an+ surface finishes% Ec -In!icat rs (Ec Scan# This is soft.are--ase+ analysis that "ro2i+es 2ery goo+ accuracy an+ the 2arious im"acts are merge+ into a single figure for con2enience% The soft.are is -uilt -ase+ on an e#tensi2e +ata-ase of en2ironmental im"act of 2arious materials an+ "rocesses% The soft.are is a2aila-le as Eco!can% This is a reasona-ly fast metho+ reFuiring a-out one to t.o +ays3 "ro2i+e+ that the +ata of im"act is a2aila-le% Benefits f Ec Design 3 !a2ing on ra. material an+ energyD Re+ucing the .eight of the "ro+uct an+ the "ackaging .ill no +ou-t re+uce the strain on the natural resources an+ sa2e energy use+ in the "ro+uction "rocess% Elimination of e#"ensi2e en+-of-"i"e solutionsD Intro+ucing conce"tslike close+ loo"s .ill re+uce the amount of .aste generate+ an+ hence the amount of .aste to -e treate+% This .ill re+uce the costs relate+ to effluent

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treatment "lants an+ their maintenance% It .ill also re+uce the strain of legal com"liances as .ell% Increase+ com"etiti2eness through use of ne. an+ im"ro2e+ technologies in "rocess an+ "ro+uctsD <onsumers are al.ays looking for ne. features in a "ro+uct% 0aking the "ro+uct en2ironmentally frien+ly an+ cost effecti2e .ill +efinitely -ring in more sales% Re+uce risks from on an+ off site treatment3 storage an+ +is"osal of to#ic .asteD 9e are continuously trying to eliminate the use of ha>ar+ous su-stances in our "ro+ucts an+ "rocesses% This .ill also en+ the associate+ "ro-lem of +ealing .ith to#ic .aste% Im"ro2e+ health an+ safety of em"loyeesD 0inimi>ing to#ic su-stances3 re+ucing .aste to -e treate+ etc .ill ha2e a +irect "ositi2e im"act on the health of the em"loyees% Im"ro2e+ "u-lic imageD The a-o2e mentione+ factors .ill no +ou-t enhance the image of the com"any% Peo"le are -ecoming increasingly conscious of en2ironmental "ro-lems3 an+ a++ressing these issues can +ra. "u-lic interest% &usiness health an+ staying "o.erD ny -usiness has to sur2i2e an+ sustain itself3 it cannot +o so .ithout a++ressing en2ironmental issues% En2ironmental issues -egin .ith the "ro+uct itself an+ not only en+ of the "i"e solutions thus it ensures the future of a -usiness an+ its guarantee+ "resence in the future%

A <y1ical Case St2!y ;ree . -er Ra!i - .hili1s In!ia

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This is a case .here +esigners ha2e use+ many of the eco-+esign "rinci"les to -ring out a "ro+uct that is cost efficient an+ en2ironmentally soun+ com"are+ to its "re+ecessor mo+el% 9hile the conce"t of free "o.er ra+io -ase+ on tra+itional +ynamo "rinci"le e#iste+H the +isa+2antages .ere that these mo+els .ere 2ery -ulky an+ +i+ i+eally contra+ict the easily "orta-le style% 0oreo2er the mechanical .in+ings of the +ynamo "ro2i+e+ relati2ely less "laying time an+ also "ro+uce+ a slo""y soun+ to.ar+s the en+ of re.in+% <onsi+ering these +isa+2antages as a real challenge3 Phili"s attem"te+ to intro+uce a free "o.er ra+io that .as sleeker in si>e3 ha+ longer "laying time an+ ho"e to marry t.o technologies $ickel 0etal 6y+ri+e -atteries an+ free "o.er% The Phili"s @ree Po.er Ra+io .orks on the "rinci"le of con2erting mechanical energy to electrical energy% Through the mo2ement of a rotary arm3 "o.er is generate+ through a "o.er generator3 .hich "ro2i+es the energy for the electrical circuit% &y turning the arm for 1 minute3 the ra+io .orks for )0 minutes% "art from the technical su"remacy an+ reFuirement of such a "ro+uct3 Phili"s 2isuali>e+ this to -e a -reakthrough in +e2elo"ment of en2ironmentally -enign "ro+ucts% This "ro+uct in a++ition to -eing en2ironmentally soun+ .as also likely to create a strong social im"act% Meth ! l gy Phili"s In+ia has a stan+ar+ "roce+ure for any ne. "ro+uct +e2elo"ment an+ is terme+ as the "ro+uct creation "rocess /P<P1% In the case of @ree Po.er ra+io3 the challenge .as in +e2elo"ing an in+igenous 2ersion3 .hich ha+ alrea+y +one .ell in the !outh East sian market% The main aim .as to launch a mechanically "o.ere+ ra+io for .hich the key consumer -enefits i+entifie+ .ereD :ffer consumers a solution3 .herein there is huge sa2ings on recurring cost of -atteries es"ecially in rural markets :ffer ultimate "orta-ility3 as a2aila-ility of -atteries is not a constraint an+ i+eal .here2er con2entional "o.er sources are not a2aila-le like for La.ans .ho are in the frontiers3 for families .ho go on "icnics /ur-an markets1 an+ for youth .ho are into trekking Re+uce reFuirement of +is"osal of -atteries

fter -asic a11r "al fr m the marketing team3 the marketing -rief in terms of customer reFuirements an+ com"liance to en2ironmental legal issues .as +e2elo"e+% !u-seFuently the follo.ing key features .ere enliste+ for @ree Po.er ra+io to set +irections for +esign an+ technical reFuirementsD It shoul+ reFuire no -atteries or e#ternal "o.er source for o"eration

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!houl+ -e i+eal for use on cam"ing tri"s an+ other situations .here con2entional "o.er sources are not a2aila-le% Turning the "o.er generator for 1 minute of charging shoul+ eFual a-out )0 minutes of listening3 ma#imum charge of 1 hour shoul+ eFual a""ro#imately 15 hours of continuous use% 09C!9C@0 ra+io .ith -uilt-in high efficiency "o.er generator .oul+ -e "ro2i+e+

Though con2ince+ a-out the acce"tance of the "ro+uct -y s"ecific consumers3 at this stage marketing team highlighte+ the uncertainity in marketa-ility of the free "o.er ra+io as it .as a ne. conce"t an+ suggeste+ that minimum risk shoul+ -e taken in terms of in2estment in +e2elo"ment of this ne. "ro+uct% &ase+ on this +irection the technical s"ecifications3 cost "arameters3 an+ +etailing of the "rocess .ere .orke+ out% This is the most crucial an+ also the +ecisi2e stage .here the "ro5ect "rocee+s further only if the "ro+uct is a11r "e! t 7e technically feasi7le% Ven+or +e2elo"ment .as also +one at this stage% These acti2ities .ere 5ointly +one -y the initial "urchasing grou" an+ the R&7 / u+io1 +e"artments% t this stage the technical reFuirements an+ costing .ere .orke+ out for @ree Po.er ra+io on the follo.ing linesD 8enerator feasi-ility - .hether the generator is feasi-le to -e in+igenously ma+e 7efining style an+ function Technology o"tions a2aila-le to make the "ro+uct !tu+y of e#isting relate+ com"onents

In the +e2elo"ment of @ree Po.er ra+io the ne#t ste" .as to translate the consumer nee+s into a tangi-le aesthetic "ro+uct .ith +ue consi+eration to ergonomics3 a""ro"riate materials3 consumer -uying tren+s3 en2ironmental consi+erations etc% The in!2strial !esign team "re"are+ a -rief consisting of -enchmarking3 "ricing an+ technical -rief to +esign the "ro+uct consi+ering some of the follo.ing "arametersD *se of common moul+ Aess material !im"le assem-ly Aess tooling

Phili"s has their esta-lishe+ stan+ar+ +esign gui+elines for consi+eration in +e2elo"ment of a ne. "ro+uct or mo+ification an+ u"gra+ation of the e#isting "ro+uct% 4ee"ing in min+ the +esign -rief +efine+ for @ree Po.er ra+io an+ the stan+ar+ +esign gui+elines3 the conce"t sketches .ere ma+e to illustrate +ifferent mo+els% 9hile +oing +esign +etailing for the selecte+ fe. o"tions3 some key consi+erations for en2ironment .ere carrie+ out 2i>% minimum scre.s3 sim"le +esign3 stan+ar+i>e+ materials an+ com"onents3 ease of assem-leC+isassem-ly3 ease of +is"osal etc% :nce the "rototy"e of the "ro+uct .as ma+e3 a usa-ility stu+y .as con+ucte+ to assess the ergonomics3 consumer -eha2ior an+ en2ironmental "rofile3 su-seFuent to .hich interfacing an+ 2ali+ation .ith engineering an+ +esign team .as +one%

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This is .here the marriage of the +etailing of ne. "ro+uct an+ the use of e#isting tools of "re2ious mo+els is consi+ere+ for o"timal in2estment an+ ma#imum use of a2aila-le resources% In case of @ree Po.er ra+io the areas for re.orkCre+esign .ere i+entifie+% This acti2ity .as a "art of the conce"t +e2elo"ment stage for R&7 / u+io13 .here they stu+ie+ the mechanical an+ electrical "ro"erties% The selection of materials an+ "rocesses are -ase+ on the com"anyEs stan+ar+ an+ central "roce+ures for intro+uction of ne. materials an+ "rocesses% The consoli+ation of -rief .as carrie+ out in this stage an+ this marke+ the en+ of all research .ork% The conce"t3 its s"ecifications an+ "rices .ere fro>en an+ a +ocument .as signe+ -y all rele2ant "arties% The +etailing of mechanical3 electrical an+ "ackaging com"onents .as +one to meet the consoli+ate+ -rief reFuirements% Recycling an+ +esign as"ects .ere consi+ere+ for en2ironmental soun+ness% 9hen the "ro+uct .as intro+uce+ in the market3 the res"onse .as Fuite goo+ an+ this e#hi-its ho. an en2ironmental initiati2e can -ecome a "rofit-generating "ro5ect% Phili"s is selling 203000 sets of @ree Po.er ra+io "er month as re"orte+ -y M&usiness TimesE .hich is a self sufficient in+icator of its commercial success% 0oreo2er the social -enefits .orke+ out -y the marketing team inclu+e sa2ing of a""ro#imately a .hoo"ing 2 million -atteries from -eing +is"ose+ into the en2ironment e2ery year3 thus re+ucing a huge en2ironmental -ur+enN C ncl2!ing Remarks3 s the e#am"les cite+ a-o2e in+icate Eco-7esign hel"s the organi>ation to continuously re+uce the consum"tion of resources an+ .aste /-oth "re- an+ "ost- use .aste1 generate+ -y a systematic a""roach% The .aste that reaches the munici"al .aste stream an+ its to#ic characteristic are continuously re+uce+% The consumer -enefits from continuous im"ro2ements in energy an+ material efficiency% Eco-7esign "ro2i+es an o""ortunity to organi>ations to -alance en2ironmental reFuirements .ith consumer tastes an+ +eman+s%

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References Lose"h @iske3 7esign for En2ironment - <reating Eco-Effiecient Pro+ucts an+ Processes Ernst 2on 9ei>sacker3 mory &% Ao2ins an+ A 6unter Ao2ins3 @actor @our B 7ou-ling 9ealth3 6al2ing Resources <lau+e @ussler an+ Peter Lames3 7ri2ing Eco-Inno2ation shok Loshi3 A% Ramakrishnan an+ $i2e+ita !arnaik3 0onogra"h on En2ironmental 0anagement !ystem I!: 140013 In+!earch3 Pune /20041 Aife <ycle Engineering 8ui+ance 0anual for In+ian In+ustry3 Tetratech & &attelle3 $e. 7elhi /200)1

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