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Dear readers, Making our products constitutes an upward value chain. From wires and optical fibers we make cables and cable systems. We are conscious of our corporate responsibility towards the environment and society and are continually stepping up our efforts in this area. Our plant in Bad Ktzting was Europes first wire and strand manufacturer, as long ago as 1996, to be validated pursuant to EMAS. Since 1998 LEONI has been presenting its environmental performance in this division in the form of environmental indicators. The Wire & Cable Solutions Divisions environmental reports have since then each covered a period of 4 years. This third environmental report covers the years from 2007 through 2010. At the end of 2006, 13 LEONI organisational units at 11 locations in six countries were DIN ISO 14001 certified. In the meantime we have steadily broadened and improved the environmental management system at our facilities around the world. Even during the economically difficult period (from the end of 2008 to mid 2009), we prepared more facilities for ISO 14001 certification, where this was obtained for the first time. At the time of the editorial deadline in June 2011, a total of 23 LEONI organisational units within the Wire & Cable Solutions Division in nine countries China, Mexico, the United Kingdom, Slovakia, Turkey, Poland, Hungary, Switzerland and Germany were thus certified to the ISO 14001 environmental management standard.
CERTIFICATE
The Certification Body of TV SD Management Service GmbH certifies that
has established and applies an Environmental Management System. An audit was performed, Report No. 70770193 Proof has been furnished that the requirements according to
ISO 14001:2004
are fulfilled. The certificate is valid until 2014-04-23 Certificate Registration No. 12 104 39456 TMS
Jrgen Kniffki
Contents
The LEONI Group and Wire & Cable Solutions Systematic environmental management Green technology Data collection within the various business groups Business Group Automotive Cables Business Group Industry & Healthcare Business Group Communication & Infrastructure Business Group Electrical Appliance Assemblies
Enclosure of Certificate No.: 12 104 39456 TMS
Sites
LEONI Kabel Holding GmbH Stieberstrae 5 D-91154 Roth LEONI Draht GmbH Treuchtlinger Strae 20 D-91781 Weienburg LEONI Draht GmbH Windorfer Strae 1 D-93444 Bad Ktzting Haarlnder GmbH Regensburger Ring 14 D-91154 Roth LEONI Kabel GmbH Stieberstrae 5 D-91154 Roth LEONI Cable (Changzhou) Co. Ltd. Futian Industry Park, No. 109, Hanjiang Road, Xinbei District PRC-213022 Changzhou / Jiangsu LEONI Kbelgar Hungaria Kft. Klcsey F. u. 53 H-3000 Hatvan LEONI Cable S.A. de C.V. Ave. Rio Conchos No. 9700 MEX-31530 Cuauhtmoc LEONI Kabel Polska Sp. z o.o. ul. Olawska 10, Wierzbice PL-55040 Kobierzyce LEONI Kablo ve Teknolojileri Sanayi ve Ticaret Ltd. Sirketi Bursa Serbest Blgesi TR-16600 Bursa LEONI Slowakia spol. s.r.o. SNP 60 SK-01851 Nov Dubnica Trenianska Tepla, ast Dobr SK-91401 Dobr SK-97228 Valask Bel LEONI Cable (Xiamen) Co. Ltd. No.666, Yang Guang Road Xin Yang Ind. Hai Cang PRC-361022 Xiamen Design, manufacturing and sales of cables, cable assemblies, harnesses and power cord sets
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Scope of application
Design, development, production and sales of wires, cables, cable assemblies, components and cable systems Design, development, manufacture and sale of copper and copperbased alloy conductors (wire, bunches, braiding wire, strands and ropes) with bare, tin or silver plated surfaces Manufacture of copper and copper-based alloy conductors (wire, bunches, braiding wire, strands and ropes) with bare, tin or silver plated surfaces Manufacture and sale of stranded conductors, tinsel conductors, braided copper straps, knitted copper fabrics, woven copper tapes, earthing tapes and flexible connectors with terminals, low-voltageconductors and -cables Design, development and manufacturing of wires, stranded wires and automotive & electrical cables Design, development and manufacturing of wires, stranded wires and automotive & electrical cables
Scope of application
Development, production and sales of cables, cords and compounds Design and development, manufacturing, sales, engineering services as well as services related to Cables, Accessories, Assemblies, mechanical and electrical Components, Cable Harnesses, Cable Systems and Subsystems for all Applications in the Business Units Telecommunication Systems, Healthcare and Industrial Solutions Design and development, manufacturing, sales as well as services related to Cables, Accessories, Assemblies, Cable Harnesses, Cable Systems and Subsystems for all Applications in the Business Units Telecommunication Systems, Healthcare and Industrial Solutions Production of cable systems and accessories for automation and drives, medical devices, telecommunication, aerospace and marine technologies with central functions of development and sales in Roth and Friesoythe (Germany) Development, production and sales of taylor-made cables
Business Group Conductors & Copper Solutions Summary: Wire & Cable Solutions
LEONI Special Cables (Changzhou) Co. Ltd. No. 21 Taihu West Road, New Area PRC-213022 Changzhou / Jiangsu
LEONI Cable Slovakia spol. s r.o. Nm. Dr. A. Schweitzera 194 SK-91601 Star Tur LEONI Kabel GmbH - Industrial Solutions Stieberstrae 5 D-91154 Roth LEONI Fiber Optics GmbH Stieberstrae 5 D-91154 Roth j-fiber GmbH Im Semmicht 1 D-07751 Jena j-plasma GmbH Im Semmicht 1 D-07751 Jena Im Natal 7 D-07751 Jena FiberCore Machinery GmbH Im Semmicht 1 D-07751 Jena
Design, development and manufacturing of wires, stranded wires and automotive & electrical cables Design, development and manufacturing of wires, stranded wires and automotive & electrical cables Design, development and manufacturing of wires, stranded wires and automotive & electrical cables Design, development and manufacturing of wires, stranded wires and automotive & electrical cables
Development, manufacturing and sales of glas,- POF,- and PCFfiber optic cables Development, Production and Sales of Optical Fibers and Preforms; Marketing of Knowhow and Technical Support Development, Production and Sales of Silica Glass as well as Specialty Preforms
Outlook22 Contact22
Design, manufacturing and sales of cables, cable assemblies, harnesses and power cord sets. Rewinding and pre-selection of precious-metal threads. Polishing and testing of drawing dies
Development, production and selling of manufacturing plants for production of fiber optic cables
The Wire & Cable Solutions Division The LEONI Groups structure involves a holding company and two business divisions. The organisational structure of these divisions is in essence geared to their customer groups and markets. The Wire & Cable Solutions Division (WCS) is one of the two divisions and encompasses all business involving wires and cables.
Central Services
Automotive Cables
You will find information on the markets in the sections covering the individual business groups.
Holding
products and processes we ensure that environmental harm is largely avoided, that emissions and waste are reduced and that resources are used sparingly. We undertake to adhere to all pertinent environmental laws and directives as well as internal rules of conduct. We maintain an open dialog with customers, authorities and the general public about issues within our Company that relate to the environment. We urge our business partners to follow environmental guidelines comparable to our own and we advise our customers on environmentally friendly ways to handle and dispose of our products. We regularly evaluate the status of environmental protection within our Company as well as the technical and organisational
Locations, plants
Environmental policy at LEONI We acknowledge that, as a commercial enterprise, we share a special responsibility for safeguarding the natural essentials of life. It is our aim to strike a balance between peoples aspirations, environmental concerns and the interests of our Company. Environmental protection consequently is a mandatory element of our business activity at LEONI. Business success and ecological responsibility are no contradiction in terms for us. We rate environmental protection among our primary business objectives and include it in LEONIs quality policy. The environmental compatibility of processes and products is raised by incorporating them in our continuous improvement process (German abbr.: KVP).
procedures thus required in order to identify weaknesses, to initiate the required measures and to document the progress that has been made. We raise the level of safety at work by identifying and removing potential sources of danger to people and the environment. Health and safety at work as well as environmental protection are closely interlinked and work practice-related formulation of processes usually also results in enhanced environmental compatibility. We ensure, with appropriate environmental management, that our environmental policy is applied effectively. Environmentally aware thinking that is conveyed to our various locations by our environmental management prevails at the facilities of the Wire & Cable Solutions Division.
Green technology
Green technology
What exactly does green technology mean? Also described as environmental technology, the term represents products and services that enable businesses to operate more energy efficiently and be more sparing with resources; to reduce emissions and thereby to further increase the environmental compatibility of all their processes. Demand for environmentally compatible and sustainable technologies (green technology) continues to rise unabated. LEONI has set itself the goal of becoming the most innovative cable manufacturer for environmentally friendly technologies. Yet how is green defined? There is a very favourable trend in green technology especially for German companies, which in many cases lead the global market in this respect. Customers are increasingly calling for green products and ever more environmental legislation is coming into force worldwide. The proportion of patents with reference to green technology is continually rising. Investors are also increasingly basing their decisions on how companies are dealing with the challenges of climate change and environmental protection. The six global trends of particular importance to LEONI i.e. the growing population & demographic change, urbanisation, globalisation, environmental awareness & shortage of resources, industrialisation & automation as well as mobility - present the Company with both ecological and economic challenges. We have thus geared our portfolio of products and services to six principal markets for environmental technologies that have, on the basis of scientific studies, been identified as markets of the future. LEONI does not just pay lip service to sustainability. We are the first cable manufacturer to have developed a holistic concept for green technology. We thus define all products and system solutions as well as services that contribute to lowering greenhouse gases or serve as a contribution to specific environmental technologies that control air and water pollution. In so doing, we rate our activities according to the following three criteria: Socially Raising the awareness of employees and business partners Economically Strengthening of our customer base through innovative, technology-driven products and solutions Ecologically Improvement of environmental performance through innovative products and solutions of both divisions LEONI is making a significant contribution in three ways Where do we stand with green technology right now? More than two years ago, both of our divisions extrapolated the global trends to future growth areas for LEONI as part of their strategic planning. Since 2010 we have successfully applied the interlinking of global trends with our strategy and green technology to position LEONI under the motto of mobility and the environment. We shall continue this for 2011 under the motto of urbanisation and the environment and will present a further trend with very specific solutions by LEONI.
Product: Use of environmentally compatible raw materials that comply with national and international guidelines Process: Environmental certification of the facilities in our worldwide production network to ensure optimum energy and resource efficiency in the manufacturing process Application: Use of our products and solutions in defined markets to achieve greater energy efficiency and CO2 reduction
Green technology
Six target markets for green technology Environmentally friendly energy generation and storage Efficiency of raw and other materials Sustainable mobility
Energy efficiency
Recycling management
Water consumption [l] / product [kg] Waste water [l] / product [kg]
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Data collection
ISO 14001-certified facilities The following facilities are ISO 14001 certified: Roth (Germany) with 545 employees, Hatvan (Hungary) with 136 employees, Nov Dubnica (Slovakia) with 40 employees, Wierzbice (Poland) with 295 employees, Gemlik (Turkey) with 61 employees, Changzhou (China) with 115 employees and Cuauhtmoc (Mexico) with 200 employees. The plan for the medium term is to prepare the two facilities in Halver (Germany) with 62 employees and in Casablanca (Morocco) with 35 employees for ISO 14001 certification. Highlights of the environmental management system
The following facilities were certified to the ISO 14001 environmental management system for the first time during the period under report: Nov Dubnica (Slovakia) in November 2007, LEONI Kabel Turkey in December 2007 and Changzhou (China) in June 2009 Set-up of a Business Group Automotive Cables environmental indicators system The individual facilities of our business group applied various new measures to achieve far-reaching and sustained environmental conservation, such as
Cisterns Cooling systems, cooling towers and cooling water insulation systems Improvement of waste water technologies and water treatment systems Measures to improve emulsion filtration New, improved drive technologies on the production lines PVC recycling of waste materials of value Energy saving lighting technology Improvement of the smoke alert system A more efficient steam generator Systems to recover exhaust gases Noise insulation cabinets Investment in measuring equipment to check the compressed air network, emissions and pollution involving noise and air Peripheral equipment, for example investment in compressed air regulation, conveyor equipment for new transport and logistic systems, waste separation systems and insulation systems
Data collection
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The environmental indicators All processes in this business group certainly merited favourable presentation. Success was mostly also evident in terms of waste minimisation. At only a few facilities did the switchover to a product portfolio geared to specialist customers, longer test phases as well as smaller batch sizes exert the opposite effect.
CO2 emission [ kg / product kg ] 0.8 0.6 0.4 0.2 0 2007 2008 2009 2010
Electricity consumption [ kWh / product kg ] 0.8 0.6 0.4 0.2 0 2007 2008 2009 2010
Other energy sources 1 [ kWh / product kg ] 0.20 0.15 0.10 0.05 0 2007 2008 2009 2010
Water consumption [ l / product kg ] 3.5 3.0 2.5 2.0 1.5 1.0 0.5 0
Waste water [ l / product kg ] 3.5 3.0 2.5 2.0 1.5 1.0 0.5 0
Production waste 2 [ kg / product kg ] 0.08 0.06 0.04 0.02 0 2007 2008 2009 2010
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Data collection
Data collection
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The environmental indicators The main reason for the increase in electricity consumption and other energy sources in the years from 2009 is the shift away from large volume products and heavy FlexLine ones. The products made instead involve a far larger number and more complex work steps. Furthermore, a new heating system as well as additional, high power consuming compressors went into operation at our Chinese facility in 2008.
CO2 emission [ kg / product kg ] 1.2 1.0 0.8 0.6 0.4 0.2 0 2007 2008 2009 2010
Electricity consumption [ kWh / product kg ] 1.2 1.0 0.8 0.6 0.4 0.2 0 2007 2008 2009 2010
Other energy sources 1 [ kWh / product kg ] 0.6 0.5 0.4 0.3 0.2 0.1 0 2007 2008 2009 2010
Water consumption [ l / product kg ] 2.5 2.0 1.5 1.0 0.5 0 2007 2008 2009 2010
Waste water [ l / product kg ] 2.5 2.0 1.5 1.0 0.5 0 2007 2008 2009 2010
Production waste 2 [ kg / product kg ] 0.08 0.06 0.04 0.02 0 2007 2008 2009 2010
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Data collection
At present, our facility in Dniken, Switzerland, which employs about 100 people, has seven electron accelerators with power ranging from 0.5 to 10 MeV as well as one pallet gamma sterilisation line. An additional sterilisation line that is based on x-rays was commissioned in 2010. Our newly established facility in Bautzen, eastern Germany, runs an electron accelerator. A second accelerator is already in the process of being set up. Innovative technologies will safeguard tomorrows energy supply. Our Business Unit Energy & Communication makes the connection for the future - global energy supply is one of the major challenges of the immediate future. Renewable energy sources have to be developed and new standards have to be established. We are conscious of this task and are committing ourselves with innovations, quality products and services for efficient energy generation and distribution. ISO 14001-certified facilities Our locations in Stolberg (Germany) und Dniken (Switzerland) are already ISO 14001 certified. Our facilities in Hard (Switzerland), Riedstadt (Germany), Bautzen (Germany), Codogno (Italy) and Monticelli dOngina (Italy) are not yet ISO 14001 certified. Highlights of the environmental management system
Our Stolberg facility was commended for ECOPROFIT operation in the Aachen region in 2009 Lighting management old, conventional technology replaced with modern, electronically-governed equipment. A centralised energy management system was set up Use of thermostat-controlled switch cabinet ventilators Staff involved in the environmental management system by way of training sessions and an ideas competition Systemic start-up scrap reduced by optimising processes and technology The need for action to carry out energy-related buildings refurbishment examined after evaluating gas consumption, as compared with the degree day figures Plastics recycling improved
Data collection
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Select environmental indicators The main reason for the increase in specific consumption within Business Group Communication & Infrastructure was the smaller number of orders received for various products, thus resulting in less capacity utilisation.
CO2 emission [ kg / product kg ] 1.0 0.8 0.6 0.4 0.2 0 2007 2008 2009 2010
Electricity consumption [ kWh / product kg ] 1.0 0.8 0.6 0.4 0.2 0 2007 2008 2009 2010
Other energy sources 1 [ kWh / product kg ] 0.60 0.50 0.40 0.30 0.20 0.10 0 2007 2008 2009 2010
Water consumption [ l / product kg ] 12.0 10.0 8.0 6.0 4.0 2.0 0 2007 2008 2009 2010
Waste water [ l / product kg ] 12.0 10.0 8.0 6.0 4.0 2.0 0 2007 2008 2009 2010
Production waste 2 [ kg / product kg ] 0.08 0.06 0.04 0.02 0 2007 2008 2009 2010
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Data collection
ISO 14001-certified facilities Business Group Electrical Appliance Assemblies produces at four locations (one plant in Slovakia, two plants in China and one in Spain). Two of these production facilities (LEONI Xiamen in China and LEONI Nova Dubnica in Slovakia) are ISO 14001 certified. We are aware of the responsibility we share and protect natural resources as well as the foundations of life. Our aim is to strike a balance between respect for nature and achieving business objectives. Environmental protection is a key element of our Companys activity. Highlights of the environmental management system
By adjusting the size of sea containers used at our Chinese facilities we achieved savings in logistics of between 15 and more than 30 percent. In collaboration with various household appliance manufacturers, Business Group Electrical Appliance Assemblies has developed environmentally-friendly, halogen-free assembled cables and launched its LEONI EcoSense trademark in 2010. By making use of waste heat from compressors at our Slovakian facility we managed to heat processing water on a permanent basis as well as to feed excess heat into building heating during the winter. This achieved substantial savings on electrical energy.
BSH Bosch and Siemens Home Appliances Electrolux Philips Miele Black & Decker Vorwerk Bosch Panasonic Toshiba
We realised further energy savings by means of cooling water management that is geared to the outside temperature.
Thanks not least to the commitment of our 2500 employees, Business Group Electrical Appliance Assemblies to a large extent implemented the ISO 14001-compliant environmental management system and steadily broadened it. The ISO 14001 environmental standard was already established years ago at the relevant production sites.
Data collection
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Select environmental indicators Business Group Electrical Appliance Assemblies, in particular, is able despite the difficult situation in 2009 to report an onthe-whole positive trend in its figures.
CO2 emission [ kg / product kg ] 0.8 0.6 0.4 0.2 0 2007 2008 2009 2010
Electricity consumption [ kWh / product kg ] 0.8 0.6 0.4 0.2 0 2007 2008 2009 2010
Other energy sources 1 [ kWh / product kg ] 0.08 0.06 0.04 0.02 0 2007 2008 2009 2010
Water consumption [ l / product kg ] 1.4 1.2 1.0 0.8 0.6 0.4 0.2 0
Waste water [ l / product kg ] 1.4 1.2 1.0 0.8 0.6 0.4 0.2 0
Production waste 2 [ kg / product kg ] 0.04 0.03 0.02 0.01 0 2007 2008 2009 2010
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Data collection
Data collection
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Select environmental indicators The commissioning of high-tech machinery (tin-plating line for solar braids; multi-wire drawing line for nickel-plated wires) as well as setting up of high power consuming plant (rolling mill) temporarily causes less productive circumstances. Yet this requires resources such as electrical power and water, which is why these key indicators are partly on a downward trajectory. Drawing processes involve high power consumption and cause waste heat, which in the winter months is used to heat the production shops. During the period of weak capacity utilisation from the end of 2008 to early 2009 this effect had to be compensated with more use of oil and gas. Consumption of other energy sources was therefore up.
CO2 emission [ kg / product kg ] 2.0 1.5 1.0 0.5 0 2007 2008 2009 2010
Electricity consumption [ kWh / product kg ] 2.0 1.5 1.0 0.5 0 2007 2008 2009 2010
Other energy sources 1 [ kWh / product kg ] 0.4 0.3 0.2 0.1 0 2007 2008 2009 2010
Water consumption [ l / product kg ] 1.6 1.2 0.8 0.4 0 2007 2008 2009 2010
Waste water [ l / product kg ] 1.6 1.2 0.8 0.4 0 2007 2008 2009 2010
Production waste 2 [ kg / product kg ] 0,10 0.08 0.06 0.04 0.02 0 2007 2008 2009 2010
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Summary
Electricity consumption [ kWh / product kg ] 0.8 0.6 0.4 0.2 0 2003 2004 2005 2006 2007 2008 2009 2010
Water consumption [ l / product kg ] 5.0 4.0 3.0 2.0 1.0 0 2003 2004 2005 2006 2007 2008 2009 2010
Waste water [ l / product kg ] 5.0 4.0 3.0 2.0 1.0 0 2003 2004 2005 2006 2007 2008 2009 2010
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Outlook
Contact
Outlook
Energy: Production requires energy! It will in the future become increasingly important, in the wake of steadily rising energy demand, to give greater weight to the subject of energy management, which is tied closely to the subject of environmental management. This means not losing sight of differing factors always from a commercial aspect. The principle is to consider renewable energy not only when buying electrical power or to always acquire the best possible technology with respect to production plant, but also to take a structured approach in continual execution of energy-saving projects. Energy efficiency means, at constant output, reduction of the energy used by means of continual improvement of various processes. Sustainability: LEONI defines sustainability as working in a commercially, environmentally and energy aware manner. This includes the environmental compatibility of products as well as the behaviour of all employees with respect to environmentally aware dealing with all resources. With respect to the development opportunities of upcoming generations, we also call for and support sustainability in the area of research and development. Copper: The raw material of copper is one of the main components of our products. That is why we vigorously pursue raw material efficiency in this respect. We continually strive towards minimising production waste in our everyday work. Insulation materials: Insulation materials are another key element. We develop and produce cable insulation compounds in line with legal requirements (REACH, RoHS) and according to customer specifications with respect to banned substances. In addition, we have developed compounds in which ecologically dubious elements have been substituted. Future insulation materials will have more favourable properties; along with being flame retardant and partly self-extinguishing, the compounds are halogen free and resistant to mechanical strain.
Contact
This Environmental Report advises the public, especially our customers and employees, on our environment-related activity. Please feel free to contact us if you have any questions or suggestions concerning this topic. We will answer any of your questions concerning the environment and energy that you email to: umwelt@leoni.com. This report is available for download (also in German) to all interested persons and groups from our website at www.leoni. com. You will find further information on the subject of the environment on our website.
About
Published by:
Conceptual design / editor: Eva Schuster Coordination: Dated: Karl-Heinz Brkel Quality & Environmental Management June 2011
Our special thanks go to all colleagues who contributed to preparing this report.
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Stieberstrasse 5 91154 Roth Germany Phone +49 9171-804-0 Fax +49 9171-804-2200 E-mail cable-info@leoni.com www.leoni.com