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A Lifecycle Assessment of the Supply Chain and Evaluation of End-of-Life Management Options Wednesday, April 2, 2008
Project Significance Increase in shoe  =   Increase in environmental production/consumption  impacts (production/disposal) Number of shoes produced world-wide in 2004 12 billion pairs Projected world- wide production by 2010 20 billion pairs Average pair of shoes owned per person in the U.S. 10 pairs Total U.S footwear sales, 2005  $42 billion United States footwear consumption 2005 1.4 billion pairs Average amount of shoes disposed in landfill per year  ~ 104 million pairs
What’s in a Typical Shoe PET EVA Adhesives Nylon 6 Virgin Rubber Conventional Cotton Metal Eyelet Leather
Simple Shoes
The $64,000 Question ,[object Object],[object Object]
Project Objectives ,[object Object],[object Object],[object Object],[object Object]
Methodology and Approach ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
The Four Products Shoe 1  GREEN TOE Shoe 2  GREEN TOE Shoe 3  ecoSNEAKS Shoe 4   Conventional Sneaker
What’s in a Simple Shoe? Vamp/ Upper Laces &  Tongue Sock Liner Heel Outsole Midsole Insole
Natural Latex 34% Crepe 38% PET 4%  Bamboo 4% Cotton 4% Hemp 17% Percentage of Materials  by Weight Shoe 1 Green Toe
Virgin Rubber 32 % Recycled Car Tire 29 % Organic  Cotton 7% EVA 5% PET 11% Nickel 2% Latex 5 % Hemp 14% Shoe 3 ecoSNEAKS Percentage  of Materials  by Weight
Cotton  16% Cow Suede 15% EVA 5% Jute 1% Virgin  Rubber 55% Misc. 4% Nickel 1% PU Foam 1% Percentage  of Materials  by Weight Shoe 4 Conventional Shoe
Manufacturing a Simple Shoe Cutting Stitching Gluing Finishing Packaging Stages of Assembly
 
Why Life Cycle Assessment? ,[object Object],[object Object],[object Object],[object Object]
Building our LCA ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Shoe Assembly Material Production Packaging Transportation Disposal
Environmental Impact Categories ,[object Object],[object Object],[object Object],[object Object],Radioactive Radiation Ozone Layer  Depletion Potential Photochemical Ozone  Creation Potential Global Warming Potential Human Toxicity Potential Freshwater Toxicity Potential Terrestrial Toxicity Potential Eutrophication Potential Marine Aquatic  Toxicity Potential Acidification Potential DALY Kg ethane-eq Kg DCB-eq Kg CO2-eq. Kg R-11-eq. Kg SO2-eq. Kg phosphate-eq.
 
 
Life Cycle Assessment Interpretation Environmental Impact Categories Shoe Styles AP [kg SO2-Equiv.] EP [kg P-Equiv] FAETP [kg DCB-Equiv.] GWP [kg CO2-Equiv.] HTP [kg DCB-Equiv.] Shoe 1 0.0171 0.0033 0.0402 1.672 8.482 Shoe 3 0.0092 0.0015 0.0414 1.808 10.469 Shoe 4 0.0695 0.0179 0.1623 7.51 41.03   Shoe Styles ODP [kg R11-Equiv.] POCP [kg Ethene-Equiv.] RAD [DALY] TEPT [kg DCB-Equiv.] MAETP [kg DCB-Equiv.]  Shoe 1 1.48E-06 3.99E-03 1.40E-08 39.42 140.25 Shoe 3 7.10E-07 1.12E-0 3 1.54E-08 48.51 266.61 Shoe 4 7.59E-07 1.68E-03 1.95E-08 190.96 796.12
In “Simpler” Terms Shoe Style GWP is Equivalent to driving a Car (19mpg) for… GWP is Equivalent to powering a 60W Light Bulb for… How about mileage for the world projection of shoe production… Shoe 1 3.9 mi 29 hrs ~70 Billion Miles Shoe 3 4.2 mi 31 hrs ~84 Billion Miles Shoe 4 17.4 mi 129 hrs ~300 Billion Miles
Methodology for identifying opportunities    to “ green ” the existing supply chain  ,[object Object],[object Object],[object Object],[object Object]
Analyzing the Supply Chain  Existing vs. Extended Raw Materials Extraction Primary Materials Production Component Manufacture Finished Product Assembly Product  Sale and Delivery Product  Use Product Disposal Supply Loop? Existing Supply Chain Extended Supply Chain
Analyzing the Supply Chain “Greening” the Supply Chain through Materials Substitution
Analyzing the Supply Chain “Greening” the Supply Chain through Materials Substitution Material Amount (MJ) Crepe Rubber 0.30 Hemp 2.44 Organic Cotton 16.18 Ethylene Vinyl Acetate (EVA) 16.57 Cotton 18.77 Polyethylene Terephthalate (PET) 22.77 Polyurethane (PU) Foam 27.63 Silicon Rubber 47.25 Nylon 6 55.59 Leather 56.95 Source:  PE International (GaBi 4.0) Extended DB
Analyzing the Supply Chain   Targeted Actions - Results ,[object Object],[object Object],[object Object],[object Object]
Assessment of the Economic and Environmental Benefits of Materials Substitution Original Material  –  Shoe 4 Alternative Material  –  Shoe 1 Environmental Impact 1 Economic Cost 2 Laces Cotton Organic Cotton Jute Outsole Rubber Crepe Rubber Retreaded Car Tires Midsole EVA Wool Felt Cork No Data Recycled PET Insole/Liner Cotton Bamboo  Upper Suede Hemp Jute Wool Felt Adhesives Chemical-Based Adhesives (Phenol/Urea) Water-Based Adhesives
End-of-Life Evaluation: Methodology ,[object Object],[object Object],[object Object]
End-of-Life Evaluation: Collection Options ,[object Object],[object Object],2900 km 2900 km 10 km 2.68 kg CO2 eq. 0.08 kg CO2 eq. 0.08 kg CO2 eq.
End-of-Life Evaluation: Four End-of-Life Options ,[object Object],[object Object],[object Object],[object Object],[object Object],End-of-life Options compared to Landfilling Current Practice - Landfill  –  Positive GWP due to anaerobic emission of methane. Additional environmental Impacts including air and groundwater pollution (GWP = 0.27 kg CO2 eq.)   Net GWP  (kg. CO 2  eq.) (pair of shoes) Feasibility supply chain steps shipping distance (km) take-back Reuse 0.17 1 426 yes Recycling .94 2 16000 yes Grinding  -1.48 1 1535 yes  Composting -0.27 0 0 no
Composting The “ Simple ” Option ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Benefits No Take-Back ,[object Object],[object Object]
Conclusions ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Acknowledgements ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Questions?

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Life Cycle Assessment of Footwear for Simple Shoes

  • 1. A Lifecycle Assessment of the Supply Chain and Evaluation of End-of-Life Management Options Wednesday, April 2, 2008
  • 2. Project Significance Increase in shoe = Increase in environmental production/consumption impacts (production/disposal) Number of shoes produced world-wide in 2004 12 billion pairs Projected world- wide production by 2010 20 billion pairs Average pair of shoes owned per person in the U.S. 10 pairs Total U.S footwear sales, 2005 $42 billion United States footwear consumption 2005 1.4 billion pairs Average amount of shoes disposed in landfill per year ~ 104 million pairs
  • 3. What’s in a Typical Shoe PET EVA Adhesives Nylon 6 Virgin Rubber Conventional Cotton Metal Eyelet Leather
  • 5.
  • 6.
  • 7.
  • 8. The Four Products Shoe 1 GREEN TOE Shoe 2 GREEN TOE Shoe 3 ecoSNEAKS Shoe 4 Conventional Sneaker
  • 9. What’s in a Simple Shoe? Vamp/ Upper Laces & Tongue Sock Liner Heel Outsole Midsole Insole
  • 10. Natural Latex 34% Crepe 38% PET 4% Bamboo 4% Cotton 4% Hemp 17% Percentage of Materials by Weight Shoe 1 Green Toe
  • 11. Virgin Rubber 32 % Recycled Car Tire 29 % Organic Cotton 7% EVA 5% PET 11% Nickel 2% Latex 5 % Hemp 14% Shoe 3 ecoSNEAKS Percentage of Materials by Weight
  • 12. Cotton 16% Cow Suede 15% EVA 5% Jute 1% Virgin Rubber 55% Misc. 4% Nickel 1% PU Foam 1% Percentage of Materials by Weight Shoe 4 Conventional Shoe
  • 13. Manufacturing a Simple Shoe Cutting Stitching Gluing Finishing Packaging Stages of Assembly
  • 14.  
  • 15.
  • 16.
  • 17. Shoe Assembly Material Production Packaging Transportation Disposal
  • 18.
  • 19.  
  • 20.  
  • 21. Life Cycle Assessment Interpretation Environmental Impact Categories Shoe Styles AP [kg SO2-Equiv.] EP [kg P-Equiv] FAETP [kg DCB-Equiv.] GWP [kg CO2-Equiv.] HTP [kg DCB-Equiv.] Shoe 1 0.0171 0.0033 0.0402 1.672 8.482 Shoe 3 0.0092 0.0015 0.0414 1.808 10.469 Shoe 4 0.0695 0.0179 0.1623 7.51 41.03   Shoe Styles ODP [kg R11-Equiv.] POCP [kg Ethene-Equiv.] RAD [DALY] TEPT [kg DCB-Equiv.] MAETP [kg DCB-Equiv.] Shoe 1 1.48E-06 3.99E-03 1.40E-08 39.42 140.25 Shoe 3 7.10E-07 1.12E-0 3 1.54E-08 48.51 266.61 Shoe 4 7.59E-07 1.68E-03 1.95E-08 190.96 796.12
  • 22. In “Simpler” Terms Shoe Style GWP is Equivalent to driving a Car (19mpg) for… GWP is Equivalent to powering a 60W Light Bulb for… How about mileage for the world projection of shoe production… Shoe 1 3.9 mi 29 hrs ~70 Billion Miles Shoe 3 4.2 mi 31 hrs ~84 Billion Miles Shoe 4 17.4 mi 129 hrs ~300 Billion Miles
  • 23.
  • 24. Analyzing the Supply Chain Existing vs. Extended Raw Materials Extraction Primary Materials Production Component Manufacture Finished Product Assembly Product Sale and Delivery Product Use Product Disposal Supply Loop? Existing Supply Chain Extended Supply Chain
  • 25. Analyzing the Supply Chain “Greening” the Supply Chain through Materials Substitution
  • 26. Analyzing the Supply Chain “Greening” the Supply Chain through Materials Substitution Material Amount (MJ) Crepe Rubber 0.30 Hemp 2.44 Organic Cotton 16.18 Ethylene Vinyl Acetate (EVA) 16.57 Cotton 18.77 Polyethylene Terephthalate (PET) 22.77 Polyurethane (PU) Foam 27.63 Silicon Rubber 47.25 Nylon 6 55.59 Leather 56.95 Source: PE International (GaBi 4.0) Extended DB
  • 27.
  • 28. Assessment of the Economic and Environmental Benefits of Materials Substitution Original Material – Shoe 4 Alternative Material – Shoe 1 Environmental Impact 1 Economic Cost 2 Laces Cotton Organic Cotton Jute Outsole Rubber Crepe Rubber Retreaded Car Tires Midsole EVA Wool Felt Cork No Data Recycled PET Insole/Liner Cotton Bamboo Upper Suede Hemp Jute Wool Felt Adhesives Chemical-Based Adhesives (Phenol/Urea) Water-Based Adhesives
  • 29.
  • 30.
  • 31.
  • 32.
  • 33.
  • 34.