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Introduction

Reducing material usage, or dematerialisation, means that as little material as possible is used. This reduction in materials can be for the product itself, the product packaging or the distribution packaging. Excess material usage wastes materials, money and landfill space.

Dematerialisation can be through miniaturisation, light weighting or physical to digital services (e.g. digital photos, books, movies, music, forms, etc) (Lennart and Ljungberg, 2005)

It is believed that product design changes alone could reduce material use by 30% Link

Benefits

  • Reduced raw material costs
  • Lower distribution costs and emissions
  • Less storage space required
  • Reduced packaging so less waste for recycling, re-processing and landfill
  • The potential to pass on cost savings to the consumer

More information on reducing packaging here

Considerations

ConsiderationChallengeOpportunity
Durability of product or packaging could decreaseProduct or packaging could fail potentially impacting safety and/or financial lossThorough design, modelling and testing will mitigate the risk
Costs could increase with the change to product or packagingHigher spec material or production costs could outweigh the material reduction savingPrior cost benefit analysis would give certainty to the decision

Product Design

Reducing product material usage:

  • Ensure product is designed for its environment, without unnecessary over specifications
  • Use higher strength materials, allowing less material to be used –life cycle analysis required
  • Optimized cross-sectional shapes of structures to achieve better loading performance
  • Only reinforce areas which require additional strength, not the entire product

(Mayyas et al, 2012)


Reducing packaging:

  • Refillables, e.g. printer cartridges
  • Reformatted product, e.g. paint powder
  • Concentrates, e.g. concentrated drinking squash
  • Product packaging and sizing fit for customer, e.g. smaller bread loaves
  • Product shape, e.g. reshaping biscuits to fit better in packaging
  • Reusable packaging, e.g. reusable carrier bags

More information on reducing packaging here

Case studies

  • Graphic Design

    Jaguar Land Rover completed a Life Cycle Analysis which showed CO2 emissions accounted for 75% of the life cycle impact. A lighter weight aluminium body structure and reduced engine weight allows higher fuel efficiency for the cars, whilst delivering the same performance. Link

  • Graphic Design

    Apple have reduced their packaging for the iPhone by 28% since 2007. They are now able to transport 60% more phones in the same container; saving material costs, transportation costs and emissions whilst retaining protection to the phone. Link

Introduction

A technical product is usually made of one or several materials and the sustainability of those materials needs to be considered through the entire life cycle (Lennart and Ljungberg, 2005).

Selection of material is traditionally made by technical demands like price, strength of material, temperature stability, hardness, etc. (Brechet Y et al, 2001 & Mangonon 1999) However, for a successful sustainable product development, factors like reputation, fashion, product, cultural aspects, etc. must also be taken into account (Ljungberg, 2005).

Optimisation of materials can include:

1. Replacement of Technical for Biological materials - This allows materials to be composted or used to create biogas, avoiding the need to cycle materials. Biological materials can include wood, cardboard, paper, sugarcane, hemp etc. An example is a compostable carrier bag or paper packaging.

2. Use of recycled material - Using recycled materials closes the materials loop and can be a cheaper alternative. Recycled materials can include metals, plastics, ceramics and composites (Ljungberg, 2005). A common example of recycled material is in plastic drinks bottles.

3. Removal of toxic materials - Depending on the materials and substances, a material could be potentially toxic for human health throughout its life cycle phase or specifically at the end of its life. Concerning the potential toxicity in the pre-production, production and usage phases, if a material does not release harmful substances during these phases, it is possible to define it as being biocompatible. (Allione et al 2011)

4. Eco-efficient materials - Are materials which have low environmental impact. Eco-efficiency includes the embodied energy (direct and indirect energy used to make the materials, energy to transport the materials and recoverable energy from combustion) and CO2 emissions to produce and deliver the materials (Allione et al 2011). For example, replacing plastic for metal may improve the eco-efficiency of the product, depending on the application.

5. Reduction of scarce materials - Dependence on scarce materials introduces supply risk and creates an unsustainable product in the medium to long-term. Although replacement of one material for another might not reduce the material volume, it reduces the dependency on the potentially costly and emissions-intensive process of mining the material. Materials on the European Commission critical raw materials list include: Antinomy, Cobalt, Gallium, Geranium, Indium, Platinum, Palladium, Niobium, Neodymium and Tantalum. Link. The redesign of Neodymium in magnets for electrical motors is an example of how scarcity of materials is affecting design.

Benefits

Potential benefits include:

  • Reduced virgin raw material consumption
  • Good reputation
  • Financial benefit
  • Reduced material sent to landfill
  • Lower emissions and pollution
  • Lower supply chain risk (Ljungberg, 2005)

Considerations

Consideration
Challenge
Opportunity
Cost to change the designPotentially high costs are possible for development, production and purchase of materialsChange to design could improve customer satisfaction, green credentials and supply chain risk
Change to design could impact product functionality or durabilityProduct or packaging could fail potentially impacting safety and/or financial lossThorough design, modelling and testing will mitigate the risk

Product Design

Products with highly optimised materials will have high proportions of:

  • Biological materials/nutrients
  • Recycled materials
  • No toxic materials
  • Eco-efficient materials
  • Abundant materials

Case Studies

  • Graphic Design

    M&S have a chocolate range where the tray will totally compost, or if left under running water it will totally breakdown.Link

  • Graphic Design

    Puma have developed a trainer which is 100% biodegradable Link

  • Graphic Design

    Ribena bottles made totally of recycled material Link

  • Graphic Design

    Polartec use recycled plastic bottles to produce their REPREVE 100 range of clothing which is made from 100% recycled materials Link

  • Graphic Design

    Toyota are developing a neodymium-free electric motor for its expanding range of hybrid cars, which doesn’t use rare-earth materials such as Neodymium Link

Introduction

Industrial symbiosis is the physical exchange of materials or energy between companies; waste from one company becomes the resource for another company. Cooperation between companies can lead to “win-win” situations where there is competitive advantage for both companies. The key to industrial symbiosis are collaboration and the synergistic possibilities offered by geographic proximity (Chertow, 2000).

Benefits

Potential benefits include:

  • Reducing resource use, dependence on non-renewables, pollutant emissions, and waste discharges
  • Reducing input, production, and waste management costs, and generating additional income due to value added to by-product and waste streams
  • Improving relationships with external parties, and by facilitating development of new products and their markets
  • Generating new employment, and helping to create a safer and cleaner natural and working environment (Mirata, 2004).

Considerations

Consideration
Challenge
Opportunity
Developing exchanges and interactions with other companiesDifficult to find and form synergies with partner companiesOrganisations like the NISP Network and International Synergies can help. Also, building an understanding of your raw materials, waste products, local users and purchasers will find opportunity
Quality of supply/feedInconsistent raw materials or waste product can affect product qualityControls, measures and treatment can regulate inbound and outbound quality
Knowledge sharing of waste stream composition Competitors knowing composition or volume of waste products could compromise secrecy If it is an issue, controls and measures with the partner company can protect company information
Legal regulations around the movement of waste materialsRegulation of hazardous materials could prevent industrial symbiosisRegulations will cover certain substances, but it will still be feasible for many materials and substances

Product Design

Industrial symbiosis can be for a wide variety of materials, providing there is a user who needs that input material, industrial symbiosis is possible. Materials include water, heat, steam, ash, paper, sawdust, card, oil, minerals, metals, etc. (Chertow, 2007)

Case Studies

  • Graphic Design

    Tata Steel create blast furnace slag as a by-product from the steelmaking process. The slag is then used as a cheaper alternative than road stone, to create tarmac. The tarmac processing site is based inside the steelworks to reduce transportation costs. Link

  • Graphic Design

    British Sugar carefully use their by-products to produce sugar, electricity, tomatoes, animal feed, lime, bioethanol and more. The previous wastes from the company now generate revenues through working with local companies. Link

  • Graphic Design

    Procter & Gamble now achieve zero waste to landfill from 45 of their factories, by finding other companies who need the material. Paper scrap is being transformed in to roof tiles and shampoo waste is converted to industrial fertiliser. Globally, 99% of all materials are turned in to finished product or are reused, recycled or converted in to energy. Link

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