1 Freiburg and Glenrothes Locations Preserving what we value Micronas to EMAS/ISO 14001
2 2 Micronas Sustainable environmental protection Safeguarding the long-term future of our sites Editorial Our company continued to develop positively in fiscal year 2012, and it was in fact the most successful year for us since we began focusing on automotive and industrial electronics. Especially in the automotive segment, Micronas managed to increase its sales and earnings compared with the previous year, posting a double-digit EBIT margin of 14.4% was characterized by a number of positive changes, such as the founding of the Innovation Center under the leadership of Klaus Heberle, and the complete repositioning of the Automotive Business Center under the management of Dr. Dirk Behrens as Vice President Automotive, with the aim of bringing new products to market even faster. We have been able to successfully position our product line of embedded controllers for smart actuators on the market and in 2012 we began with their large-volume delivery. Our leading product here is the HVC 2480B, which is used, for example, in automated grill modules (AGM) for vehicles. The AGM is positioned directly in front of the vehicle s radiator and regulates the supply of cooling air through the angle of the ventilator flaps. This function continuously guarantees an optimum engine operating temperature and enables improved aerodynamics through the targeted deflection of the driving air flow in relation to vehicle speed. These benefits result in lower fuel consumption. The latest generation of our GAS 86xyB gas sensors, which are based on the unique proprietary mysens technology, has been extremely well-received by the market. They enable the simultaneous detection of two gases and the integrated measurement of ambient temperature and atmospheric humidity despite their much smaller size and much lower power consumption than their predecessors. Furthermore, they are based on the proven, inexpensive standard CMOS manufacturing technology, which allows the sensor elements for gas, temperature and moisture measurement to be combined on one chip. Both these lead products are manufactured in the QFN package line that was newly installed at the Freiburg site in The outstanding feature of this package form is that the electrical connections (pins) do not extend on the side beyond the mold package, but are integrated flat into the underside of the housing. This means we can offer our customers inexpensive package forms that save an enormous amount of space compared with the usual surface-mounted devices (SMD). The newly installed QFN package technology opens up innovative packaging possibilities for our semiconductor devices and meets both current and future market requirements. With the installation of the QFN line, we have secured direct access to this technology and thus taken another step towards safeguarding the future of the Freiburg production site over the long term. Last year, in conjunction with our customer DENSO, we celebrated delivery of the 500 millionth Hall sensor to the automotive industry. This means that, in all, Micronas has supplied the automotive and industrial electronics market with more than two and a half billion Hall sensor solutions, a fact that makes us particularly proud. Micronas products are based on topnotch technologies and comply fully with the mega-trends of environmental protection and safety. We are committed to sustainable environmental protection not only with our products but also with our clean production methods. We hold all the necessary operating permits. With our ESF management system, we are already well positioned, but we constantly strive to improve our environmental performance even further. In last year s EnvironmentalNews, we told you about our energy management system, and this year we would like to introduce you to our water resource management system. On the next page, you will find out more about two water projects that have already been successful. Matthias Bopp Chief Executive Officer
3 Micronas 3 Water resource management possibilities, potentials, advantages Environmental Projects The water resource management team (l. to r.): Misu Ratescu, Christian Mueller (team head), Konrad Slowik and Michael Schöllhorn Life as we know it would be impossible without clean water. Industrial production, our social well-being and our health have been dependent on it for over 150 years. In 2011, by launching a flagship initiative called Resource Efficient Europe as part of the Europe 2020 campaign, the EU committed itself to the sustainable management of water as a vital resource. Details of this are given in the blueprint of November 2012 on the safeguarding of Europe s water resources. Water resource management To supplement the energy management initiative started by Michael Schöllhorn in 2011, a water resource management project was launched last year by Dr. Christian Mueller. It pursues a holistic approach: to reduce consumption and minimize costs for energy and water the two most important resources for Micronas. In the EU s new blueprint to safeguard water resources, the newly established water resource team identified three key measures for Micronas that could be actively and positively influenced: water conservation, the efficient use of water, and transparency. Water conservation The philosophy behind the conservation of (waste) water is simple: What is not discharged into the water does not subsequently have to be removed from it at additional cost. Successful waste water treatment requires extensive know-how on the optimum management of the water/effluent flows. It also requires knowledge of the substances contained in the waste water and above all those not contained in it. At Micronas, the waste water is efficiently separated according to its quality and quantity into five substreams. In the first part of the project, the team determined what substances were actually contained in the waste water. Based on current regulations to protect the aquatic environment, several hundred undesirable substances in the natural water environment were recorded and compared with the listed Micronas substances. The results showed that only a few thousandths of the undesirable substances in natural water are discharged with the waste water into the public sewage system. The concentrations are so low that they would even be negligible for natural waters. Water efficiency There are two ways of using water efficiently: Firstly, to use as little water as possible in production processes, and secondly, to recover and recycle as much of this water as possible from production. At Micronas, a system for recycling the reclaim water has been in place for many years now, leading to savings of up to 20% of the fresh water requirement. The reclaim water is then fed, for example, to the recooling units of the building s airconditioning system. In the second part of the project, the team therefore looked at the potential savings in ultra-pure water treatment. When drinking water is treated to turn it into ultra-pure water, so-called concentrate streams are generated, which are thrown away. After a detailed analysis of the water flows and water quality, possibilities were found for internal recycling. It is now possible, for example, to return the concentrate stream of the ultrafiltration process (particle retention) ahead of the reverse osmosis (retention of salts and molecules). All these measures combined can yield savings of approx. 10% in water treatment. new new 1 st Stage 2 nd Stage 3 rd Stage Ultra-pure water treatment Requirement without 2 nd project Requirement with 2 nd project before Transparency Transparency requires a thorough knowledge of the key water management data. These are essentially the volume, quality and frequency of the water needed and the waste water produced. Transparency also means disclosing the facts to an interested public. Micronas satisfies both requirements. Summary The two projects described in this article looked at ecological and economic issues concerned with water resource management. They have since been implemented, saving valuable resources and bringing financial benefits to Micronas. The purity of our waste water complies with present and future requirements, and the waterconserving possibilities have been identified and implemented.
4 4 Micronas Overview of current and planned projects Freiburg Location Environmental Projects Subject Goal Measure Dept. responsible Energy management 1) 250,000 kwh / year (40 t CO 2 / year) Introduction of heat exchangers for free cooling in winter in parallel with the chillers Plant Engineering and Facilities 10,000 kwh / year (2 t CO 2 / year) Electricity saving by relocation of hazardous substances in the warehouse and optimization of the electric power consumption of the fan 15,000 kwh / year (3 t CO 2 / year) Electricity saving in probing/final testing of linear Hall sensors through the use of dualcore controllers Backend Engineering 100,000 kwh / year (16 t CO 2 / year) Automatic power management on PCs and laptops 100,000 kwh / year (20 t CO 2 / year) Electricity savings through introduction of Thin Clients IT Operations 270,000 kwh / year (54 t CO 2 / year) Electricity savings in the computer center through virtualization Immission control Use of refrigerants with low to zero ozone-depletion potential Refrigerant plants to be switched from R22 to alternative refrigerants Plant Engineering and Facilities Resource management Waste reduction by using new reagents in the treatment of galvanic waste water Use of bentonites and Fe-III chloride Plant Engineering and Facilities Reduction of water consumption by 10% in ultrapure water production Efficient guiding of the water / waste water streams in the 5-step treatment facility Saving of approx. 1.4 t of chemicals per year by process optimization Introduction of throughput of controlled bath changes in electroplating Backend Operations Future savings of 250 kg / year copper lead frames in compression mold cleaning Use of paper strips instead of lead frames in compression mold cleaning Saving of approx. 150 l / year (tin concentrate hazardous to aquatic environment, additives, acids) Savings of chemicals by low-flow filtration Backend Assembly Occupational safety Increase in occupational safety, savings of tin and cleaning chemicals, waste reduction in electroplating Substitution of the mechanical/ chemical process through a melting process in the cleaning of the tin cathode and recycling of tin Backend Operations Increase in occupational safety, chemical/waste re duction Cleaning of small components in self-enclosed cleaning box for small parts Health protection Improved health protection Initiation of activity courses to build up muscles and initiation of Shiatsu treatment Working group on health protection 1) Calculation of the CO 2 savings is dependent on the electricity mix of the power supplier in the relevant year Legend: Implementation Extension Completed, goal achieved
5 Micronas 5 Micronas at a Glance Micronas at a Glance FACTS AND FIGURES Micronas in 2012 Headquarters of holding company in Zurich, Switzerland (SIX Swiss Exchange: MASN) Operational management and production in Freiburg, Germany 893 employees worldwide, of which 788 work at the operational headquarters in Freiburg Test center in Glenrothes (Scotland) Sales of CHF 168 million / EUR 140 million Micronas is an Authorized Economic Operator (AEO) and regarded as particularly reliable and trustworthy. The aim is to safeguard the continuous international supply chain from the manufacture of a product to the end-user. In 2012, Micronas received the status of Known Consignor. This status, which is based on the European legislation, is an important step against terrorism in civil air freight. Investment and ongoing expenditures of EUR 1.4 million in corporate environmental protection (waste management, water protection, soil decontamination, noise reduction, air pollution control, climate protection, nature protection, landscape conservation) Sales distribution according to production lines Sales distribution by region Europe 28 % Asia 64 % America 8 % Micronas Certificates Sensors 92 % Controllers 5 % other products 3 % EUR million ISO Freiburg ISO Glenrothes Test center in Glenrothes (Scotland) 70 employees Energy consumption: 3.1 GWh, equivalent to 1,500 t CO 2 Main waste fractions: 3 t paper and board, 3 t plastics, 5 t metal into recycling No notifiable accidents EMAS Freiburg AEO Freiburg
6 6 Micronas Environmental Data 2012 Environmental Data 2012 The following charts show the 2012 environmental data for the Freiburg site, which is the Micronas headquarters and its largest production site. By publishing these figures, we comply with the requirements of regulation (EC) no. 1221/2009, the so-called EMAS regulation. The bar charts show the absolute consumption figures, while the linear diagrams show the consumption normalized to the total gross value added the so-called core indicators. The core indicators themselves are then related to the year Normalization to the total gross value added over the last four years ensures the required comparability of the consumption data. Other environmental data for 2012: The natural gas consumption of approx. 20,500 MWh according to GEMIS 1) corresponds to equivalent emissions of 35 kg of SO 2, 2,000 kg of NO X, and 24 kg of dust which are considered as insignificant environmental aspects The sealed area (core indicator biological diversity) is 39,200 m 2, the unsealed area is 12,300 m 2. The recycling quota for the entire waste produced in 2012 was 83 %. Total energy consumption from renewable sources and their proportion of the annual total consumption: GWh 30% GWh 50% GWh 45% 2012 Figure not yet available The photovoltaic unit installed at the end of 2011 generated around 318,000 kwh in Occupational safety and health protection At Micronas in Freiburg, the accident figures are well below the comparative index of the Employers Liability Insurance Association. In 2012, there were four minor reportable accidents, with- Micronas Freiburg BACKEND Absolute consumption Verbrauch pro Normalized Package Unit Consumption related to the total annual gross value added in %, normalized to the year 2012 Electricity and fossil fuels 174% % Consumption fossil fuels in GWh Consumption electricity in GWh Consumption related to total annual gross value added 20.5 Water 145% Consumption in 1,000 m 3 105% Chemicals Process Gases Consumption in t Consumption in t 117% 86% 96% 98%
7 Micronas 7 Electricity and fossil fuels Electricity and fossil fuels 174% Consumption fossil fuels in GWh 174% Consumption fossil electricity fuels in in GWh Consumption electricity related to in GWh Consumption total annual gross related value to added total annual gross value added 106% 106% Water Water 145% 145% Consumption in 1,000 m 3 Consumption related in 1,000 to mtotal 3 annual gross value added 105% 105% Environmental Data out 63.5 any particularly 60.8 frequent 57.6 occurrence in any one area. We regularly Bicycle checks of companies 379 on 376 the Micronas Tech Help with car/ride sharing Automatic alarms from rented areas check 2009whether 2010 hazardous substances nology Park are connected to the Sponsorship of activities 2009 for sports can 2009 be replaced 2010by non-hazardous hazard 2011 alert system 2012 of Micronas groups: running (participation in materials (principle of substitution). (hand fire extinguishers, smoke Freiburg (half) marathon), cycling, alarms, gas detection linked with Where legal changes are made to bans Chemicals indoor soccer Process Gases automatic emergency switch-off and Chemicals or to the regulation of substances e.g. Process Gases Consumption in t Consumption clearance in t of buildings) in Appendix XIV and Consumption XVII of related in t the to total REACH annual gross value added Consumption related in t to total annual gross value added regulation 2), we check and document Building evacuation drills with the fact 117% employees of rental firms and that these substances are contained neither in 86% our products nor in Emergency management 117% 96% 98% Micronas 86% 96% 38 exercise drills with 98% the 26 members of the emergency task force 1) Global emissions model for integrated systems the raw and auxiliary materials used for their production. Training of six new safety officers 2) Regulation (EU) no. 1907/2006 of the European who act in production areas as officers in charge in an emergency on the Registration, Evaluation, Authorization Parliament and Council of December 18, 2006 Environment and transport, sports Bus 590and rail timetables event and Restriction 6.2 of Chemicals 6.9 (REACH), Annex 6.2 XVII: Restrictions 6.9 on the manufacture, Subsidies 2009 for 2010 regional 2011 tickets for 2012 Training of 92 persons 2009in the handling of fire extinguishers 2010 placing 2011 on the market 2012 and use of certain dangerous substances, preparations and public 2009 transport articles WASTE Waste in t Waste related to total annual gross value added in %, normalized to the year 2012 Hazardous waste (t) Non-hazardous waste (t) Hazardous waste (t) Other waste for disposal Non-hazardous waste (t) Other waste for disposal Other waste for disposal recycling Other waste for disposal recycling Other Solvents waste for disposal for recycling Other Wood waste for disposal for recycling 117% Solvents for disposal recycling Wood for disposal 117% Solvents Acids for for disposal 155% recycling Acids for disposal recycling 155% Acids for recycling % 86% % % 87% 87% Steel scrap for recycling Plastics Steel scrap for recycling for recycling Paper Plastics for for recycling recycling Paper for recycling CO 2 -EQUIVALENTS CO 2 equivalents CO 2 equivalents related to the total annual gross value added in %, normalized to the year 2012 CO 2 equivalents in 1,000 t CO 2 equivalents in 1,000 t Emission source PFC gases Emission source elecricity PFC gases Emission source elecricity 141% energy 141% CO 2 emissions to gross CO 2 emissions value added to gross 90% value added 90% ACCIDENTS Notifiable accidents per 1,000 employees Accidents Accidents Index of the employers liability insurance association Index of the employers liability insurance association Micronas Index Micronas Index
8 Environmental Statement The next consolidated EnvironmentalStatement will be submitted for validation at the latest in July Environmental Verifier / Environmental Verifier Organization The authorized environmental verifier / environmental verifier organization are as follows: Dr.-Ing. R. Beer (Permit-No. DE-V-0007) Intechnica Cert GmbH (Permit-No. DE-V-0279) Ostendstr Nuremberg Validation Dr. Reiner Beer, with EMAS environmental verifier registration number DE-V-0007, accredited or licensed for the scope 26.1 (NACE Code Rev. 2), Manufacture of electronic components and boards, declares to have verified whether the site as indicated in the consolidated environmental statement with registration number D meets all requirements of Regulation (EC) No 1221/2009 of the European Parliament and of the Council of 25 November 2009 on the voluntary participation by organizations in a Community eco-management and audit scheme (EMAS). By signing this declaration, I declare that the verification and validation has been carried out in full compliance with the requirements of Regulation (EC) No 1221/2009, the outcome of the verification and validation confirms that there is no evidence of non-compliance with applicable legal requirements relating to the environment, the data and information of the updated environmental statement of the site reflect a reliable, credible and correct image of the site activities, within the scope mentioned in the environmental statement. Nuremberg, July 2013 Dr. Reiner Beer, Environmental Expert Micronas GmbH Hans-Bunte-Strasse 19 D Freiburg P. O. Box 840 D Freiburg Germany Phone Fax Contact: Environmental Management Officer Dr. Norbert Streckfuss Phone July 2013 Order No. U E The German version is legally binding. Printed on environmentally friendly paper, composed of 50% recycled paper fibers and 50% FSC (Forest Stewardship Council) fibers. First published in July 2013
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