DyStar Sustainability Report 2010


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As a responsible company, we acknowledged that we have a critical role to play in our daily operations to reduce our impact on the environment. The Sustainability Report 2012 is a result of an extensive company-wide exercise to gather relevant data and assess our own processes and systems for making improvements. This report is a clear reflection of DyStar's commitment to sustainability.

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DyStar Sustainability Report 2010

  1. 1. Sustainability is our responsibility. At DyStar, our products and services helpcustomers worldwide reduce costs, shorten lead times and meet stringentquality and ecological specifications. Leverkusen Frankfurt LudwigshafenBangladeshDyStar Singapore Pte. Ltd. Halifax(Liaison Office) Marcq en Baroeul Milan257 (2nd Floor, B2) Kyunggi-do Porto IstanbulNavana Ville Akbar, Road No :19/A Reidsville, NC Mem Martins Barcelona Osaka Charlotte, NC Corlu Nanjing WuxiNew DOHS, Mohakhali, Dhaka-1206 Ankleshwar Omuta Cairo ShanghaiTel: +55 11 55 08 36 84 Karachi Hangzhou Naucalpan TaipeiFax: +55 11 55 08 36 23 Mexico City Navi Mumbai Dhaka Hong KongDyStar.Bangladesh@DyStar.com SamutprakarnBrazilDyStar Indústria e Comércio Singapore Jakarta 2010 SUSTAINABILITY Cilegonde Produtos Químicos Ltda. GabusAv. Eng° Luis Carlos Berrini, 164511° andar, Cidade Monções São Paulo ApiúnaCEP 04571-011. São Paulo / SP PietermaritzburgTel: +55 11 55 08 36 84Fax: +55 11 55 08 36 23 Global Headquarters REPORTDyStar.Brazil@DyStar.com DyStar Office Key Production SiteChina/Hong Kong Indonesia Agencies in 50 other countriesDyStar China Ltd. PT. DyStar Colours IndonesiaRoom 1802B-8, 18/F 22nd Floor, Menara Global BuildingYen Sheng Centre, 64 Hoi Yuen Road Jln. Gatot Subroto Kav. 27Kwun Tong, Kowloon, Hong Kong Jakarta 12930 ThailandTel: +852 29 55 33 88Fax: +852 29 55 11 88 Tel: +62 21 527 05 50 Fax: +62 21 527 05 20 Portugal DyStar Thai Ltd. Sustainability is our responsibility DyStar Anilinas Têxteis 150 Moo 8, Soi PraekasarDyStar.China@DyStar.com DyStar.Indonesia@DyStar.com Unipessoal, Lda. Sukhumvit Road Rua Manuel Pinto de Azevedo, 626 T. Taiban, A. MuangChina/Shanghai Italy 4100-320 Porto Samutprakarn 10280DyStar (Shanghai) Trading Co. Ltd. DyStar Italia S.r.l. Tel: +351 22 615 31 80 Tel: +66 2 701 48 05-86F, Building No. 20 Via delle Groane 126 Fax: +351 22 615 31 90 Fax: +66 2 701 32 59, 701 48 09201 Min Yi Road, Songjiang District 20024 Garbagnate Milanese (MI) DyStar.Portugal@DyStar.com DyStar.Thai@DyStar.comShanghai 201612 Tel: +39 02 99 44 01Tel: +86 21 37 74 63 38 Fax: +39 02 99 02 83 91 South Africa TurkeyFax: +86 21 37 74 63 39 DyStar.Italy@DyStar.com DyStar Boehme Africa (Pty) Ltd. DyStar Kimya San. Tic. Ltd. Sti.DyStar.China@DyStar.com 27 Sheffield Road Mecidiye Mahallesi Japan Willowton, Pietermaritzburg, 3201 Cenap Sahabettin Sok. No.24Egypt DyStar Japan Ltd. P.O. Box 1845, Pietermaritzburg, 3200 34718 Kosuyolu - Kadıköy / IstanbulDyStar Kimya Sanayi Ve Ticaret Ltd. 7-20, Azuchimachi I-chrome Tel: +27 33 390 81 00 Tel: +90 216 544 15 008, Abdel Rahman Ibn Ouf Str Chuo-ku, Osaka 541-0052 Fax: +27 33 390 23 18 Fax: +90 216 339 90 61Heliopolis, Cairo Tel: +81 6 62 63 66 72 DyStar.Boehme.Africa@DyStar.com DyStar.Turkey@DyStar.comTel: +20 2 26 24 35 78 Fax: +81 6 62 63 66 91Fax: +20 2 26 24 35 81 DyStar.Japan@DyStar.com Spain United KingdomDyStar.Egypt@DyStar.com DyStar Hispania, S.L. DyStar UK Ltd. Korea Sociedad Unipersonal c/o Rhodia UK Ltd.France DyStar Korea Ltd. c/Famadas, 37-57 Burrwood Way, Holywell GreenDyStar France s.a.r.l. Jin Wha Bldg. 2nd and 3rd fl. 08907 Hospitalet de Llobregat Halifax, West Yorkshire HX4 9BH15, rue des Entrepreneurs #756-1, Gojan-dong Danwon-gu Tel: +34 93 264 04 40 Tel: +44 14 22 31 37 20Lieudit « Rue des Verts Prés » Ansan City Kyunggi-do, South Korea Fax: +34 93 264 04 58 Fax: +44 14 22 31 37 2159700 Marcq en Baroeul Tel: +82 2 34 52 78 78 DyStar.Spain@DyStar.com DyStar.UK@DyStar.comTel: +33 3 20 42 31 34 Fax: +82 2 34 52 78 76Fax: +33 3 20 42 31 46 DyStar.Korea@DyStar.com Taiwan USADyStar.France@DyStar.com DyStar Taiwan Ltd. DyStar L.P. Mexico 5th Fl., No. 196, Sec. 2 9844-A Southern Pine BoulevardGermany DyStar de México S. de R.L. de C.V. Chien Kuo N. Road, 104 Taipei Charlotte, NC 28273DyStar Colours Distribution GmbH Av. Insurgentes Sur 1685 Tel: +886 2 25 16 37 77 Tel: +1 704 561 30 00Industriepark Hoechst, Bldg. B 598 Int. 501-504 Col. Guadalupe Inn Fax: + 886 2 25 16 81 99 Fax: +1 704 561 30 0565926 Frankfurt am Main Del Alvaro Obregón CP DyStar.Taiwan@DyStar.com DyStar.USA@DyStar.comTel: +49 69 21 09 0 01020 México D.F.Fax: +49 69 21 09 20 00 Tel: +52 55 53 22 51 00DyStar.Germany@DyStar.com Fax: +52 55 56 62 56 18 Information and our technical advice - whether verbal, in writing or by way DyStar.Mexico@DyStar.com of trials - are given in good faith but without warranty, and this also appliesIndia where proprietary rights of third parties are involved. Our advice does notDyStar India Pte. Ltd. PakistanPlot No. R-855 DyStar Pakistan (Pvt) Ltd. release you from the obligation to check its validity and to test our productsTTC Industrial Area 217, Dehli Mercantile Co-operative as to their suitability for the intended processes and uses. The application,Rabale, P.O. Ghansoli Housing Society, Sirajudulla Road use and processing of our products and the products manufactured by youNavi Mumbai - 400 701 Karachi – 74800 on the basis of our technical advice are beyond our control and, therefore,Tel: +91 22 61 41 90 00 Tel: +92 21 34 55 69 95-7 entirely your own responsibility. Our products are sold in accordance withFax: +91 22 61 41 90 10 Fax: +92 21 34 55 57 58DyStar.India@DyStar.com DyStar.Pakistan@DyStar.com our General Conditions of Sale and Delivery.Global Headquarters - SingaporeDyStar Singapore Pte Ltd1A International Business Park#10-01, Singapore 609933 09.0916-00.1111Tel: +65 66 71 28 00Fax: +65 66 59 13 28DyStar.Singapore@DyStar.comwww.DyStar.com
  2. 2. recycled reused 4 From Our CEO invested565 1.7tonnes of waste million cubic meters € 6.3 million on environment 6 8 About This Report DyStar Group Corporate Profile of water protection measures 16 Corporate Governance 20 Materiality Analysis We are committed to continuously seeking 23 Our Sustainability Strategy ways to reduce the impact of our own operations. We do this by taking initiatives that reduce carbon 25 Our Guiding Principles • Responsible Care emissions, shrink water footprint, minimize waste • DyStar Compliance Management • DyStar Code of Conduct and wastewater, and improve occupational health and safety at our plants. 29 Product Stewardship • REACH Implementation • Sustainable Products and Services 43 Occupational Health and Safety 45 Environmental Performance • Energy • Greenhouse Gas Emissions • Water • Wastewater • Waste 57 Employees 59 GRI Content Index
  3. 3. recycled reused 4 From Our CEO invested565 1.7tonnes of waste million cubic meters € 6.3 million on environment 6 8 About This Report DyStar Group Corporate Profile of water protection measures 16 Corporate Governance 20 Materiality Analysis We are committed to continuously seeking 23 Our Sustainability Strategy ways to reduce the impact of our own operations. We do this by taking initiatives that reduce carbon 25 Our Guiding Principles • Responsible Care emissions, shrink water footprint, minimize waste • DyStar Compliance Management • DyStar Code of Conduct and wastewater, and improve occupational health and safety at our plants. 29 Product Stewardship • REACH Implementation • Sustainable Products and Services 43 Occupational Health and Safety 45 Environmental Performance • Energy • Greenhouse Gas Emissions • Water • Wastewater • Waste 57 Employees 59 GRI Content Index
  4. 4. Twofold strategy: Reduce our own impact G3.1 Content Index - GRI Application Level C Help our customers to reduce their impact GRI Indicators (G3.1) sight. Page No. 4.2 Indicate whether the Chair of the highest governance body is also an executive officer. 16 4.3 For organizations that have a unitary board structure, state the number and gender of members 16 of the highest governance body that are independent and/or non-executive members. 4.4 Mechanisms for shareholders and employees to provide recommendations or direction to the 16 highest governance body. 4.14 List of stakeholder groups engaged by the organization. 21, 22 Our vision: 4.15 Basis for identification and selection of stakeholders with whom to engage. 21, 22 Economic performance indicators EC2 Financial implications and other risks and opportunities for the organization’s activities due toTo become the world’s most sustainable supplier of colors and climate change. 4, 20, 23, 24 Environmental performance indicatorschemicals to the global textile industry. We believe companies that put EN3 Direct energy consumption by primary energy source. 46, 47, 48 EN4 Indirect energy consumption by primary source. 46 to 50 EN6 Initiatives to provide energy-efficient or renewable energy based products and services, andsustainability at the centre of their business will be more successful reductions in energy requirements as a result of these initiatives. 32 to 36 EN8 Total water withdrawal by source. 51, 52 and have competitive edge. EN10 Percentage and total volume of water recycled and reused. 51, 52 EN16 Total direct and indirect greenhouse gas emissions by weight. 47 to 50 EN21 Total water discharge by quality and destination. 53, 54 EN22 Total weight of waste by type and disposal method. 55, 56 EN23 Total number and volume of significant spills. 56 EN24 Weight of transported, imported, exported, or treated waste deemed hazardous under the terms 55 of the Basel Convention Annex I, II, III, and VIII, and percentage of transported waste shipped internationally. EN26 Initiatives to mitigate environmental impacts of products and services, and extent of impact mitigation. 32 to 36 EN30 Total environmental protection expenditures and investments by type. 46 Social: Labor Practices and Decent Work LA1 Total workforce by employment type, employment contract, and region, broken down by gender. 57, 58 LA7 Rates of injury, occupational diseases, lost days, and absenteeism, and number of work-related 43, 44 fatalities by region and by gender. Social: Human Rights HR4 Total number of incidents of discrimination and actions taken. 57, 58 HR5 Operations and significant suppliers identified in which the right to exercise freedom of association 57, 58 and collective bargaining may be violated or at significant risk, and actions taken to support these rights. HR6 Operations and significant suppliers identified as having significant risk for incidents of child labor, 57, 58 and measures taken to contribute to the effective abolition of child labor. HR7 Operations and significant suppliers identified as having significant risk for incidents of forced or 57, 58 compulsory labor, and measures to contribute to the elimination of all forms of forced or compulsory labor. 2010 Sustainability Report - DyStar Group 60
  5. 5. GRI index Dear Valued Stakeholder, and the United Nations Global Compact Principles. We remain fullyWe self-declare this report to be a GRI G3.1 Application Level C report. committed to the principles of Responsible Care, the chemical industry’sFor more information on GRI, visit www.globalreporting.org You are reading the DyStar Group’s first Annual Sustainability Report. initiative to improve health, safety and environmental performance that We have followed the Global Reporting Initiative (GRI) framework we signed early on.G3.1 Content Index - GRI Application Level C in developing the report. The report also includes our first Carbon Footprint Report, which was prepared using the Global Greenhouse In terms of the GRI framework, we are working toward expanding the GRI Indicators (G3.1) Page No. Gas (GHG) Protocol standards. numbers of performance indicators that we report on in the coming years. Strategy and Analysis 1.1 Statement from the CEO. 4 The report builds on decades of hard work by the DyStar Group This report documents our sustainability initiatives, performance and companies to establish a responsible, sustainable and ethical progress in 2010. Performance data in this report will serve as a base Organizational Profile business. Commitment to the principles of ethics and social and benchmark against which we will measure and report progress in the 2.1 Name of the organization. 8,13 environmental responsibility has helped DyStar become a leading coming years. 2.2 Primary brands, products, and/or services. 8,10 and trusted brand in the global textiles and leather dyestuff industry. I invite you to explore this report to learn more about how our products 2.3 Operational structure of the organization, including main divisions, operating companies, Since early last year, our Group has undergone a significant and expertise reduce the impact of the textile and leather industry and 8,10 subsidiaries, and joint ventures. restructuring following change in ownership. What has not changed what we are doing to make our own operations safer, cleaner, greener 2.4 Location of organization’s headquarters. 13 is our commitment to sustainability. and better. I hope you enjoy reading the report and find the information useful. 2.5 Number of countries where the organization operates, and names of countries with either major Our vision is to become the world’s most sustainable supplier of colors 13 operations or that are specifically relevant to the sustainability issues covered in the report. and chemicals to the global textile industry. We believe companies that We are committed to an open and transparent dialogue with all our 2.6 Nature of ownership and legal form. 16 put sustainability at the centre of their business will be more stakeholders to harness all ideas and suggestions to improve our successful and have competitive edge. sustainability performance. We also look forward to receiving your 2.7 Markets served (including geographic breakdown, sectors served, and types of customers/beneficiaries). 12, 13 feedback on this report at sustainability@dystar.com. 2.8 Scale of the reporting organization. 12 Our sustainability strategy is twofold. One, reduce our own impact. Two, help our customers to reduce their impact. The former makes 2.9 Significant changes during the reporting period regarding size, structure, or ownership. 8 our operations safer, cleaner and more efficient. The latter wins Regards, 2.10 Awards received in the reporting period. 10 customers’ confidence, and helps them in their drive for efficient Steve Barron Report Parameters manufacturing. 3.1 Reporting period (e.g., fiscal/calendar year) for information provided. 6 We are committed to continuously seeking ways to reduce the 3.2 Date of most recent previous report (if any). 6 impact of our own operations. We do this by taking initiatives that 3.3 Reporting cycle (annual, biennial, etc.) 6 reduce carbon emissions, shrink water footprint, minimize waste and wastewater, and improve occupational health and safety at our plants. 3.4 Contact point for questions regarding the report or its contents. 6 3.5 Process for defining report content. 6, 18, 20 On the other hand, we are committed to helping our customers to Chief Executive Officer 3.6 Boundary of the report (e.g., countries, divisions, subsidiaries, leased facilities, joint ventures, minimize their environmental impact. We do this by developing and DyStar Group 6 introducing innovative products and application techniques that suppliers). See GRI Boundary Protocol for further guidance. reduce energy and water use for our customers. A number of ecological 3.7 State any specific limitations on the scope or boundary of the report (see completeness principle dyestuffs that we offer help our customers to produce sustainable 6 for explanation of scope). apparel and textiles such as organic clothing. 3.8 Basis for reporting on joint ventures, subsidiaries, leased facilities, outsourced operations, and Our focus on developing innovating ecological solutions and reducing other entities that can significantly affect comparability from period to period and/or between 6 our own environmental impact helps our customers and us to address organizations. global warming concerns. 3.10 Explanation of the effect of any re-statements of information provided in earlier reports, and the This year’s report contains several examples of how we implement reasons for such re-statement (e.g., mergers/acquisitions, change of base years/periods, nature of Not applicable our twin sustainability strategy. business, measurement methods). 3.11 Significant changes from previous reporting periods in the scope, boundary, or measurement Going forward, we have committed to closely monitoring the way Not applicable we use resources including raw materials and packaging in order to methods applied in the report. identify potential opportunities to optimize resource consumption or 3.12 Table identifying the location of the Standard Disclosures in the report. 59, 60 find more sustainable substitutes. Governance, Commitments, and Engagement Our plans include progressively aligning our sustainability approach 4.1 Governance structure of the organization, including committees under the highest governance with the principles of ISO 26000 Guidance on Social Responsibility 16, 18 body responsible for specific tasks, such as setting strategy or organizational oversight.59 2010 Sustainability Report - DyStar Group
  6. 6. Employees by country 16% 3% 3% 30% 4% 5% 21% 19% China Germany Indonesia India disability, age or sexual orientation. DyStar does not tolerate Brazil USA Singapore Others behavior that is sexually coercive or threatening. Note: Percentage may not add up to 100% due to rounding.F. Disciplinary Practices DyStar does not engage in or support the use of corporal punishment, Employees by gender: 2010 mental or physical coercion and verbal abuse of its employees.G. Working Hours DyStar complies with applicable laws and standards relating to working hours.H. RemunerationI. DyStar ensures that the wages paid always meet at least legal or 26% 74% industry minimum standards.II. DyStar does not tolerate labor-only contracting arrangements and false apprenticeship schemes.I. Management SystemsI. The commitment to conform to this declaration is set out in a directive in the company’s Management System. DyStar regularly reviews and checks the adequacy and effectiveness of this directive and strives to improve the contents.II. DyStar works to ensure that suppliers and sub-contractors also act according to this declaration insofar as it is within its power to do so. Male 74%III. DyStar analyses and responds to every infringement of this formal obligation in the company. Female 26%IV. DyStar complies with national and other applicable laws. 2010 Sustainability Report - DyStar Group 58
  7. 7. Employees About this report Our people are our core strength. We continue to employ a significant number of highly qualified scientists, chemists and functional experts and managers. We operate internationally and our workforce reflects that as well. Globally we employ staff from 35 nationalities.DyStar is a knowledge-driven company. People are at the center of our Social Accountability at DyStar This is DyStar’s first annual sustainability report. The report coversbusiness model. We rely on our people to drive product innovation, to DyStar’s social accountability principles are inspired by the International our operations in calendar year 2010. The current entity of the DyStar Audienceproduce cutting edge products that meet stringent quality and safety Labour Organization core standards and SA8000, the international Group came into being in February 2010. Therefore, the economic This report’s intended audience includes a broad range of ourstandards, to develop and deliver services worldwide that exceed standard on social accountability. data covered in the report pertains to the 11-month period (1st stakeholders. Stakeholders are individuals or groups who have thecustomers’ expectations, and above all, to keep DyStar stay ahead of February to the 31st December). However, social and environmental ability to influence, may have an interest in, or may be affected bycompetition by achieving excellence across functions. DyStar applies the following principles in its operations worldwide: performance data is for the full calendar year (Jan-Dec) as we were a company’s operations. Our main stakeholders include our employees, able to gather data for the entire year. This report has been prepared customers, suppliers and contractors, shareholders, regulatoryOur people are our core strength. We continue to employ a significant A. Child Labor using the Global Reporting Initiative (GRI) G3.1 Guidelines. Based on authorities, academics, industry associations, non-governmentalnumber of highly qualified scientists, chemists and functional experts I. DyStar does not support or tolerate child labor within its area of the GRI Application Level Criteria, we self-declare this report to be a organizations, peers in the industry, and local communities.and managers. We operate internationally and our workforce reflects responsibility. Level C report.that as well. Globally we employ staff from 35 nationalities. II. DyStar does not expose children or young workers to situations in Assurance or outside of the workplace that are hazardous, unsafe or unhealthy. The report includes social, environmental and economic performance For this report, we did not seek external assurance. However, aAt the end of 2010, DyStar employed 2713 employees worldwide. data for all facilities, business units and subsidiaries that are under sustainability expert from CSRWorks International, the consultingProduction facilities employed 57% of DyStar staff. The head office B. Forced Labor the operational and financial control of the DyStar Group. It excludes firm that we hired to assist in preparing this report, visited four ofand other sales and marketing offices accounted for the remaining DyStar does not engage in or support the use of forced labor. third party warehouses and agents. All financial figures are reported our major production plants and verified the data gathered and43% of the headcount. Of all the employees, 87% were in permanent Personnel are not required to lodge deposits or identity papers in Euro (€) unless otherwise noted. reported by the respective sites.positions. Contract workers, temporary workers and part-time workers upon commencing employment with the company.constituted the rest. Managers and supervisors constitute 25% of our The report was prepared under the direction of the DyStar Sustainability Availabilityworkforce. Number of supervised workers was 655 at production facilities C. Health and Safety Committee, which has representation from the senior executive In line with our environmental policy, we have printed a limitedor 53% of the production department headcount I. Bearing in mind the prevailing knowledge of the industry and of management. The report encompasses information relating to all number of copies of this report. A PDF version of the printed report any specific hazards, DyStar does everything it can to provide a safe DyStar activities that have a material impact on society and the is available online at www.dystar.com and healthy working environment. DyStar makes every endeavor to environment. DyStar Sustainability Committee assessed and determined Human Rights prevent accidents and injury to health. DyStar has appointed qualified the materiality, and prioritization, of the content included in this Contacts We are committed to providing a safe and fair workplace staffs who are accountable for the health and safety of all personnel. report. DyStar aims to annually report on its sustainability performance. For any questions, comments or feedback where internationally agreed human rights are respected and II. DyStar ensures employees receive regular health and safety training. on this report please email sustainability@dystar.com employees are treated with dignity. DyStar Code of Conduct III. DyStar provides clean bathrooms, appropriate staff rooms and A summarized GRI Content Index is included at the end of this and DyStar Social Accountability Principles prohibit child labor, access to potable water. report to identify the location of the standard disclosures. discrimination and forced labor. DyStar respects the rights of all personnel to form and join trade unions and to bargain D. Freedom of Association, Right to Collective Bargaining collectively. I. DyStar respects the right of all personnel to form and join trade unions and to bargain collectively. Employees are made aware of these principles through the II. DyStar ensures that the representatives of trade unions are not the company intranet and other communication channels. DyStar subject of discrimination and that they have access to their company policy requires all employees worldwide to abide by members in the workplace. the DyStar Code of Conduct and DyStar Social Accountability Principles in their dealing with colleagues, suppliers, customers E. Discrimination and business partners. DyStar does not tolerate discrimination based on race, ethnic origin, gender, religion, philosophy, political or union membership,57 2010 Sustainability Report - DyStar Group 2010 Sustainability Report - DyStar Group 6
  8. 8. Environmental performance Our waste management philosophy is guided by reduce, reuse and recycle to minimize impact on the environment. While our production sites recycle waste whenever possible, some of our waste is reused by other industries as input. DyStar Facility, Gabus Our waste management philosophy is guided by reduce, reuse and recycle to minimize impact on the environment. While our production sites recycle waste whenever possible, some of our waste is reused by other industries as input. For example, DyStar facility in Gabus, Indonesia sends its waste to two cement manufacturers who reuse the waste. In this way, 1,320 tonnes of waste from the site got second life. The initiative also helps the cement manufacturers meet their own sustainability goals. DyStar Facility, Nanjing DyStar facility in China, Nanjing has succeeded in reducing the amount of wood pallets used at the site. The site previously used wood pallets on the ground to unload heavy bags of materials from trucks. The site managers noticed that wood pallets used to get damaged under the impact after some time resulting in waste. The site then decided to install a crane to lift indigo bags from the truck to the ground. The initiative has saved wood pallets and reduced waste.Significant spillsThere we no significant spills recorded in 2010. There were though19 minor incidents of escapes from primary containment. Out of 16production sites that we operated, there were no incidents of any spillson 12 sites.Each incident of spill was thoroughly investigated to identify the rootcause and assess the impact. Measures were taken to prevent recurrence.Steps included re-training of operators, changes in standard operatingprocedures, more rigorous plant maintenance, and installing monitoringdevices to prevent overflow of material. 2010 Sustainability Report - DyStar Group 56
  9. 9. Environmental performance DyStar Group corporate profile Building on a heritage of more than 150 years of experience of textile dyes, DyStar offers customers a full range of dyes, auxiliaries and services around the world. Waste DyStar Group, a privately held company, is the global market leader In 2010, DyStar Group operated 16 production plants in 14 countries Reduce, Reuse, Recycle Reducing waste and identifying opportunities for recycling waste is an in dyes, dye solutions, performance chemicals, new technologies and including Germany, Turkey, Portugal, USA, Mexico, Brazil, South Africa, integral part of our environmental management program. We believe custom-manufacturer of special dyes & pigments. It provides products and Japan, Thailand, Indonesia, China, and India. With 38 offices around services across the whole value chain in numerous industrial sectors the world, DyStar employs over 2713 people. DyStar has a marketing recycled reducing and recycling waste is not only reduces impact on environment, 565 but also reduces costs. Generating less waste means resources are being including apparel, hosiery, automotive, carpets, leather, home upholstery, network in over 50 countries. used more efficiently. industrial fabrics, etc. Since DyStar Group is a privately held company, it is not required to Over the years, various production sites have progressively reduced the Building on a heritage of more than 150 years of experience of textile publicly disclose its financial figures. amount of waste by implementing a number of initiatives including dyes, DyStar offers customers a full range of dyes, auxiliaries and services tonnes employee training. Quality improvement initiatives have helped reduce around the world. DyStar business units of waste waste at various sites. For example, improved quality processes have resulted in reduced off-spec products effectively minimizing waste. DyStar started as a joint venture in 1995 between two leading textiles DyStar Group has a strong presence across textile and leather supply chain. Our products, services and expertise cover dyestuff, Sites also try to reduce waste by reworking off-spec products wherever dyes companies Bayer AG Textile dyes division and Hoechst AG Textile raw materials sourcing, color development, sustainable textile possible to avoid waste. dyes division. In 2000, BASF AG Textile Dyes merged into DyStar. processing, textile testing, compliance with Restricted Substance Total waste generated: 2010 List (RSL) requirements of various brands and retailers as well DyStar production sites generated 4,805 tonnes of hazardous waste The Group then embarked on an impressive expansion by strategic as compliance with a number of eco-labelling and certification in 2010, which amounted to 0.050 tonnes per tonne of production. acquisitions. In 2002, DyStar acquired Color Solutions Inc. followed by schemes. Non-hazardous waste was 3,534 tonnes or 0.036 tonnes per tonne of the acquisition of Yorkshire America Inc. in 2004. DyStar continued to production. acquire more companies to grow in strategic market segments. These included acquisitions of Rotta Group in 2005, Boehme Group in 2006 DyStar’s main business divisions are as follows: Stringent measures have been implemented at production sites for and Texanlab in 2007. 58% 42% the identification, classification, transport and environmentally safe 1. Dyes disposal of hazardous waste in compliance with local regulations. Only In February 2010, India-based Kiri Dyes and Chemicals Limited and DyStar is the world’s leading supplier of textile dyes. We have by far the licensed contractors are engaged to transport and dispose the waste. China-based Longsheng Group jointly acquired assets of DyStar Group broadest product range on the market, covering almost all fibres and out of insolvency. With this acquisition, DyStar Group shifted its business quality specifications. Our sites do not have hazardous waste treatment facility. Therefore, focus towards Asia and established itself in Singapore. hazardous waste needs to be transported to the third-party treatment DyStar offers a wide range of dyes for cellulosic, acrylics, polyamide, plants. In total, 4,805 tonnes of hazardous waste was transported out of The acquisition also saw changes in top management team at DyStar. wool and silk, polyester, and textile printing. our sites worldwide in 2010 for treatment and disposal. Steve Barron, formerly vice president-strategic marketing, was appointed the new CEO for DyStar Group. Reactive dyes Currently, licensed contractors incinerate the hazardous waste generated DyStar is a global leader in Reactive Dyes and we take our responsibility by our sites. Non-hazardous waste goes to designated landfills. Mr Weixiang Ruan, Chairman and Chief Executive Officer of the for people and the environment very seriously. As a member of The Longsheng Group became the Chairman of the DyStar Group. Ecological and Toxicological Association of Dyes and Organic Pigments Recycling waste is an important aspect of our waste management Manufacturers (ETAD), we apply the same high standards of safety Hazardous waste 58% program. DyStar sites recycled or reused 565 tonnes of waste in 2010. Kiri Holding Singapore Private Limited now owns DyStar Group. Kiri and ecology worldwide and are committed to the chemical industry’s Non-hazardous waste 42% Holding Singapore Pte Ltd is a special purpose vehicle company jointly Responsible Care principles. owned by India’s Kiri Industries Limited, and Well Prospering Limited, a subsidiary of Zhejiang Longsheng Co. Ltd., a leading manufacturer of Our well-known reactive dyes brands include Levafix®, Procion® and dyes in China. Remazol®.55 2010 Sustainability Report - DyStar Group 2010 Sustainability Report - DyStar Group 8
  10. 10. DyStar Group corporate profile Environmental performance Levafix® Dyes are versatile, high performance dyes with excellent Some of our sites have developed creative methods to reduce wastewater reproducibility and fastness properties in pale and very pale such as by changing the process of washing vessels. For example, DyStar shades. site in Brazil decreased the amount of wastewater from 255 litres per tonne of production in 2009 to 204 litres per tonne in 2010, and continues Procion® dyes guarantee maximum reproducibility and level to reduce it further. dyeing in difficult dyeing conditions. DyStar facility in Hangzhou, China reduced 60 cubic meters of wastewater Remazol® dyes offer an extensive range of economical dyes for in 2010 by recycling vessel-cleaning water. Another site in Nanjing, China cellulosic fibers with very good buildup in deep shades. started recycling high concentration mother liquid for the next batch of production thereby reducing the level of contaminants in the DyStar Facility, Wuxi Procion PX are a full range of powder and liquid dyes for reactive wastewater. The facility in Wuxi, China reduced wastewater per tonne of DyStar facility in Wuxi, China has reduced the amount of wastewater two-phase printing of cellulosic fibers meeting increasing quality and production in 2010 by 21% compared with 2008 by improving methods and emissions to wastewater by deploying creative and innovative ecology demands for apparel and home textiles. for filter bag cleaning and better production planning. methods. The Sirius L sub range meets the high light fast requirements for At the Wuxi site, we have been successfully reusing dyestuff recovered Large vessels are used in the manufacturing of dyestuff and furnishing fabrics and home textiles. from the wastewater. The innovative method developed by our site colors. The vessel has to be washed and cleaned after every engineers not only saves valuable resource in the form of recovered production cycle. The Wuxi site saw an opportunity to reduce Vat dyes dyestuff but also reduces the levels of emissions in the wastewater wastewater here. Indanthren dyes are products for cellulosic fibers. The main use of discharged. The site recovered 2,555 kg of dyestuff in 2008, 7,574 kg in Indanthren dyes is in the areas where high fastness and technical 2009 and 8,668 kg in 2010. The site engineers worked with the supply chain management properties are specifically required. Increased fastness requirements by and sales departments to improve production planning. retailers and brand textile companies support demand for Indanthren We are now looking into replicating some of these success stories at Through improved planning, now the site processes larger dyes, such as leisure and sportswear, home decoration articles. DyStar other sites in 2011. batch size for each production cycle and thereby reduces the has recently introduced an Indanthren hand tag to emphasize on its number of cleaning cycles. high fastness and ecological properties. Table 5 – Wastewater discharge data 2010 As a result, the site uses less water, generates less wastewater, Acid dyes and has more vessel time for actual production. Total wastewater discharged (m ) 3 1,749,333 Telon and Isolan dyes are for application on wool and polyamide. For wool, DyStar’s focus is on differentiated products to meet the rising Wastewater intensity per tonne of production (M3) 18.05 The site did not however stop there. It developed a method to demand for high fastness dyes. recover dyestuff from the wastewater by improving the process COD discharged (tonnes) 3038 of cleaning filter bags. While the recovered dyestuff can be reused For polyamide, DyStar offers a full product range and has an outstanding COD intensity per tonne of production 0.0313 in the next production cycles, less of it going the wastewater position in the carpet industry and growing sportswear sector. means lower emissions to water. Disperse dyes Disperse dyes are used for polyester dyeing which may include apparel, sportswear, automotive textiles, carpets and upholstery. Our disperse dyes brands include Dianix® and Palanil® which fulfill the9 2010 Sustainability Report - DyStar Group 2010 Sustainability Report - DyStar Group 54
  11. 11. Environmental performance DyStar Group corporate profile Together with our high-quality products, our expertise helps partners in the industry work without banned substances, and meet the wide range of test specifications and declarations required. Wastewater complicated technical requirements for polyester dyeing market. The As one of the world’s leading suppliers of processing chemicals and Wastewater is generated at our production sites when the water is “Dianix Green Range” of DyStar complies with the strictest Restricted dyes, we also offer our customers advice on how to optimize the used in production processes and for washing equipment. Bulk of the Substances List (RSL) requirements of the market. ecological profile of leather production and the application of our water (78%) used by our production sites is for cooling purpose which products. does not pollute water as this water does not come into direct contact 2. Auxiliaries with chemicals. DyStar offers an extensive range of textile auxiliaries grouped under Together with our high-quality products, our expertise helps partners in the following three categories: the industry work without banned substances, and meet the wide However, DyStar sites continue to find innovative ways to reduce a. SERA® process chemicals which are used in all textile preparation, range of test specifications and declarations required. Examples wastewater to minimize impact on environment. pretreatment and dyeing processes include the SG label for leather produced without toxic chemicals, b. EVO® finishing and effects chemicals, consisting of functional Oeko-Tex Standard 100 and the restricted substance lists issued by DyStar facility in Ankleshwar, India is a zero discharge plant meaning effects chemicals, water-based coating products as well as sizing various brands. no wastewater is released into the environment. A Reverse Osmosis and yarn lubricants for all kinds of fibers (R.O.) plant was added to the facility in 2008, which treats wastewater c. LAVA® denim laundry chemicals & effects products to create for reuse. At this facility, water use has also been reduced by introducing today’s and tomorrow’s denim jeans fashion Awards and recognitions use of water jet pump for cleaning of equipment, which results in less Our sustainability efforts have received recognition from water being used. 3. Services stakeholders. For example, two of our plants in China have a. Ecology Solutions: DyStar Ecology Solutions package is designed to received awards for their environmental excellence. The plant In 2010, wastewater discharged from our all production plants amounted help textile producers meet demand for responsible and sustainable in Wuxi continued to enjoy the Green Level Enterprise status to 1.75 million cubic meters or 18.05 cubic meters per tonnes of production. As part of its econfidence® program, DyStar advises in 2010, the highest level awarded by the Wuxi Environmental production. Emissions of organic substances to water measured as the customers on issues relating to ecology and recommends suitable Protection Bureau. DyStar plant in Nanjing received the Blue chemical oxygen demand (COD) were 3,038 tonnes. This translates into products to meet ecological specifications. Level Enterprise award in 2010 from the Nanjing Environmental 0.0313 tonnes of COD per tonne of production. b. Testing Solutions: DyStar service centers offer customers eco, Protection Bureau. physical, chemical and color fastness testing using international We measure wastewater and COD levels at the discharge point from test methods. DyStar subsidiary Texanlab is a leading partner in eco our plants before it is sent to third party treatment plants. While we do testing, certified to ISO 17025 and an accredited partner for international Associations some pre-treatment of wastewater at some of the sites, most of our brands and retailers. Our service lab in Frankfurt, Germany is also DyStar is a member of a number of industry associations and initiatives wastewater is channeled into licensed third party licensed wastewater certified to ISO 17025 and offers a wide range of analytical and eco to promote sustainability. Some of these include: treatment plants for further treatment. testing. c. Color Solutions: Color Solutions International, a DyStar group • International Council of Chemical Associations’ Responsible company, is a market leader in providing a variety of color solutions Care Programme to retailers and brands. CSI’s offerings include readymade colors, • The Ecological and Toxicological Association of Dyes Organic custom color matching, design tools and certified color standards Pigments Manufacturers (ETAD) for textiles, paper, plastics and packaging. • Textile Exchange (formerly known as Organic Exchange) 4. Leather DyStar makes a compact range of dyes for a wide variety of applications for the coloration of leather and fur. Our homogeneous dyes can be combined with each other to give level dyeing from pale pastels to deep, brilliant hues.53 2010 Sustainability Report - DyStar Group 2010 Sustainability Report - DyStar Group 10
  12. 12. Environmental performance We believe that investing in developing innovative ecological products and solutions reduces our market risk and places us on a stronger footing as demand for such products and services increases. Our production sites continue to find creative ways to save water. For example, DyStar site in Gabus, example, DyStar site in Gabus, Indonesia introduced recycling of wash Indonesia introduced recycling of water in the finishing department in 2009, which has reduced water consumption by 25,000 cubic meters a year or about 20% of the total wash water in the finishing department water used previously. in 2009, which has reduced water DyStar site in Wuxi, China collects steam condensate from the heat consumption by 25,000 cubic meters exchanger in the spray drying operation, which is then treated, by filtration and regeneration. The treated water is reused by the plant’s a year or about 20% of the total laboratory. water used previously. Actions taken by various sites include employee training in efficient use of water, promptly detecting and plugging water leaks and installing flow meters to monitor use of water actively. Water drawn from sources: 2010 Currently, we do not calculate water demand satisfied by the reused or recycled water. The actual volume of freshwater consumption avoided because of recycling and reuse would be higher than the 1.7 million 0.2% cubic meters reported here. We are in the midst of developing a methodology .6% that will help us reliably estimate the water demand satisfied by recycled 4 and reused water. We are also aware that recycling of water often involves increased 3 use of energy. We therefore need to examine carefully the extent to 2.2% 61.6% which water can be reused or recycled without disproportional jump in energy consumption. Using more energy would result in increased greenhouse gas emissions and higher costs. Our aim therefore is to progressively reduce our water intensity on the one hand and increase the amount of water recycled and reused to the extent possible and pragmatic. The water footprint figures for 2010 will serve as a baseline for measuring our future progress. Surface water 61.6% Utilities 34.6% Table 4 – Water intensity 2010 Ground water 2.2% Total water consumption (m3) 9,007,209 Others 0.2% Water consumption per tonne of production (M3) 92.92 Note: Percentage may not add up to 100% due to rounding.11 2010 Sustainability Report - DyStar Group 2010 Sustainability Report - DyStar Group 52
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