Optimization of the adhesives production process through installation of a new extruder unit for mixing adhesives. Result: Reduction of 30 percent in the plant’s energy consumption.

Various campaigns to motivate employees to help to save energy at the site, such as by setting maximum and minimum temperatures for air conditioners. Result: Reduction of 7 percent in energy consumption.

Extensive measures for increasing efficiency, including an improvement in the capacity utilization of mixing plants for cosmetics production. Result: Reduction of 28 percent in energy consumption.

Extensive measures to reduce the consumption of energy and water. Result: Reduction of energy consumption by 9 percent and water consumption by 13 percent.

A new technique enables washing powder ingredients to be mixed without the addition of water. The detergent therefore no longer needs to be dried in the spray tower. Result: Cut of 20 percent in gas consumption and 23 percent in water consumption.

Implementation of numerous optimization projects in all areas of adhesives production. Result: Reductions of 8 percent in electricity consumption, 22 percent in water consumption, and 14 percent in waste.

 “Excellence in Site Services” program: Launch of a worldwide effort to boost the efficiency of the infrastructures at our sites. The aim is to achieve the best possible balance between quality, safety and costs. So far we have identified more than 450 individual measures in the areas of energy, maintenance, facility management;, safety, health and environment and plant logistics. Regular workshops and intensive communication ensure the rapid sharing of best practices, thus making knowledge and experience accessible on an international scale.

Installation of a new steam-driven heat exchanger in cosmetics production. With the help of waste heat from a compressor, we now heat the test baths for hair and deodorant sprays. This enabled us to cut our gas consumption and to reduce radiation losses. Result: Energy savings of about 6 percent in 2007 – equivalent to 250 metric tons of carbon dioxide emissions.

Use of captured process heat from production to heat buildings. Part of the superheated steam from the detergent production lines is used to generate hot water to heat the raw materials warehouse. During the summer, this heat is fed into the public district heating network of the city of Vienna. Result: Reduction of carbon dioxide emissions by almost 700 metric tons in 2007.

Installation of an on-site steam generation plant as part of a comprehensive modernization project. Before, the site used to be supplied to by an external steam power plant. Considerable amounts of heat were lost as the steam was transported through long-distance pipelines, and the reliability of the supply was somewhat uncertain. Result: In addition to assuring continuity of energy supply to production, annual energy consumption was reduced by up to 30 percent.

Utilizing waste heat from a compressor that generates cold water to cool the mixing vessels for adhesive production. An analysis showed that the waste heat from the refrigerating compressor is sufficient to heat up the 50 degrees Celsius hot water necessary to clean the mixers. Results: Utilizing the waste heat from the compressor has cut gas consumption in production by 5 percent.

Installation of an on-site steam generation facility, including a steam boiler, a hot water boiler, and a feed-water conditioning system. In addition, a new network of steam, hot water and condensate recycling pipelines was laid. Result: Due to the changes in infrastructure and optimization of the building heating system, annual carbon dioxide emissions at the site were cut by about 20 percent.

Launch of a systematic energy audit program to draw up an energy balance for each site. In the future, the results should serve as decision-making criteria for approving projects and investments. Results: Possible measures identified for increasing energy efficiency include optimizing production lines, providing information and training programs for employees, and using energy from renewable sources.

Implementation of a comprehensive energy audit. With the help of a monitoring system, the main energy consumers and the root causes of high consumption were identified. Based on the results, an energy management plan was initiated. Savings were achieved by various means, such as optimizing the hot water system and eliminating leaks in the compressed air system. Result: Cut of total energy consumption at the site by 12 percent.

“Total Productive Management” program: On the basis of detailed potential analyses, quantified targets and measures to maximize effectiveness, productivity and quality while simultaneously minimizing waste, energy consumption, and maintenance costs were agreed. Given the highly promising initial results and the positive response of the employees involved, the program will be extended to additional production sites worldwide.

Since January 2005, some 12,000 industrial installations in the European Union participate in the world´s largest emissions allowances trading scheme. The objective is to achieve a reduction of 8 percent in carbon dioxide emissions in Europe (base level: 1990) by the year 2012. Henkel´s power plant in Düsseldorf-Holthausen, the Company’s largest source of direct carbon dioxide emissions, is subject to the emissions trading scheme. The power station is technically very well equipped. Its efficiency is almost 90 percent, thanks to the especially effective use of cogeneration. As early as 1990, the construction of a gas turbine brought about a reduction of approximately 25 percent in carbon dioxide emissions. With the help of further improvements in energy management and a tripling of the carbon dioxide neutral fuels from production residues, emissions per kilowatt hour of electricity and steam have been reduced by an additional 20 percent since 1990.

The features of the newly erected Henkel headquarters for China and the Asia-Pacific region are highly energy-efficient. Glass curtain walls and heat recovery circuits for the heating and air conditioning system contribute to saving energy. Result: The building consumes about 60 percent less energy than comparable structures.

Optimization of the powder detergents production to make the most energy-intensive stage - the spray drying towers - more efficient. Result: Using only a very low proportion of spray dried raw materials in our detergents has reduced gas consumption at the site by 25 percent.

Investment in a new heat recovery system for the detergent production line to recycle waste heat from production to our processes. Result: Reduction in energy consumption by about 15 percent by recovering the 100 degree Celsius waste heat from the spray drying tower and using it for our production processes.

Heating of office buildings with captured process heat from production. Result: Savings of about 1,750 megawatt-hours of energy per year, corresponding to about 350 metric tons of carbon dioxide emissions.

Comprehensive optimization of various processes at the site: Installation of a new burner in the spray-drying tower for laundry detergent, reuse of rinsing water, targeted training of employees to increase waste recycling. Result: Reduction of gas consumption by 50 percent, water consumption by 35 percent and increase in recycling rate from 10 to 86 percent.

Detailed screening of the plant’s operations for potential improvements. Result: Changes in production planning and cleaning processes helped to cut wastewater volume by more than 15 percent and gas and electricity consumption by even 40 percent.