Product Stewardship

Our Environment

Product Stewardship

Product Stewardship

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In 2000 Fuji Xerox Co Ltd made a commitment to zero waste to landfill of recovered products1which led to the establishment of recycling systems across the Asia Pacific region. This involves collecting back from our customers our products that have reached their end-of-life, for reuse, remanufacturing and recycling.

Since 2012 Fuji Xerox Australia has been achieving zero waste to landfill and we continue to look at moving more materials up the material waste hierarchy - where reuse is paramount, when the need for use in the first place is unavoidable.

Material waste hierarchy

waste

Remanufacturing has the benefit of using materials in their existing format with 50 – 90 percent of the mass typically being able to be reused directly. In house calculations have shown that remanufacturing a waste toner bottle at our Eco Manufacturing Centre saves approximately 80 percent of the carbon emissions when compared to recycling the container and purchasing a replacement bottle.

In the 14/15 year the quantity of items remanufactured at our Eco Manufacturing Centre in Australia grew by 33 percent on top of 28 percent growth in 13/14 and in 15/16 we achieved a further 17 percent growth.

Refurbished machines and remanufactured parts make up about 11 percent of our materials direct reuse with about 89 percent of materials being recycled for reuse.

Fuji Xerox Australia materials utilisation

material

In saying that, approximately 30 percent of our spare parts requirements for our Australian customers is met through remanufactured parts that meet the same tolerances as new parts. This has both significant environmental and cost benefits.

Where we are unable to reuse materials in their existing form we want to find new and innovative uses that continue to improve the environmental footprint of our products.

Paving the way to a sustainable future

In 2014 Fuji Xerox Australia became the first original equipment manufacturer (OEM) in Australia to send waste toner directly to be recycled through the joint venture between Close the Loop and Downer Group to produce a value-added asphalt additive called Modified Toner Polymer (MTP). This is residual toner extracted from waste toner bottles during our remanufacturing process.

A mixture of waste toner separated at Close the Loop in Melbourne from Fuji Xerox and other OEM’s participating in the Cartridges for Planet Ark program, as well as waste toner separated at our Eco Manufacturing Centre in Rosehill, is blended in a patented process to create MTP. The MTP is added to asphalt to create TonerPave®.

Due to the nature of the toner polymers TonerPave roads are expected to outlive conventional road surfaces due to improved resistance to rutting and cracking.

Calculations provided by Downer Group estimate about 270 tonnes of carbon emissions have been avoided by the use of TonerPave, for some 900kms of roads that have been laid to date in Australia.

By the end of the 15/16 year Fuji Xerox Australia’s Eco Manufacturing Centre at Rosehill had captured 268 tonnes of waste toner for reuse.

Previous to the TonerPave® innovation the industry standard around the globe has been to use the waste toner as an alternative fuel source in the manufacture of cement or steel.

Optimising materials recovery

We believe that used products are not waste, but rather valuable resources, and our efforts to reuse, remanufacture and recycle is based on this principle. Our aim is to achieve zero waste to landfill from devices, parts and consumables collected from our customers and to maintain our obligations under the Product Stewardship Act 2011 and associated regulations.

While zero waste to landfill is a great achievement, and our device returns process and Officecare Cartridge Recovery boxes available to all of our customers are effective, we are not naïve to the fact that some products may not return to us for reuse or recycling. We actively seek to find and collect such material, driving industry leading performance in product take back at end-of-life.

In 14/15 we turned our attention to our indirect channel sales in regional areas where there are no ‘zero landfill’ recyclers available. With help from our lead logistics provider, DHL, we reviewed the returns process for our dealerships to enhance return rates from these areas. We are now able to track and monitor returns from every regional dealership, where previously our visibility was limited. This has enabled us to pinpoint locations where we believe more returns should be arising, and encourage that material towards recycling or remanufacture. There has been great uptake in the refreshed returns process and we are now looking to develop a reliable method of measuring the return rate to quantify the amount of material we don’t receive back from regional areas.

Improving logistics through local sortation

In 2011 we moved our recycling operation onshore, after previously exporting our material to the Fuji Xerox Recycling Centre in Thailand for processing under Basel permit. All used parts and consumables, whether candidates for remanufacture or not, were then sent to Close The Loop in Melbourne for sortation, data capture and directing to recycling or remanufacturing. This came with significant logistics overheads, both in monetary and environmental cost. In 14/15 we began decentralising sortation and data capture with it now established in all capital cities. This also addresses materials collected by our regional dealerships. This process improvement reduced b-double truck movements by 32,000km in 14/15 and by 84,000km in 15/16.


Meeting our legislative obligations


Under the Product Stewardship Regulations (Televisions and Computers) 2011, importers and manufacturers of TV and IT equipment are obliged to collect and recycle a designated volume of e-waste proportional to imports or manufacture. We have been exceeding our targets since they came into full effect in the 12/13 financial year and are well positioned to meet the growing recycling targets which were raised by the government 16 percent for 16/17 over the prior year.

Fuji Xerox Australia is a founding member of the Australia and New Zealand Recycling Platform (ANZRP)which operates TechCollect, a free service, available to all household and small business consumers of electronics to drop off and responsibly recycling all in-scope e-waste.

The scheme has led to a rapidly developing electronics recycling marketplace as the volume of collected material has grown, particularly from consumer households. With this growth the requirement for recyclers to handle difficult and hazardous recyclable materials such as leaded glass and circuit boards has increased. Fuji Xerox Australia has chosen to be a reporting member through its co-regulatory body, ANZRP. As a reporting member we are able to manage the collection of end-of-life devices from our customers and ensure delivery of those devices to our recycling partner, Sims Recycling Solutions (SRS). Each year we audit SRS and it’s down streams to ensure that hazardous materials and environmental management is maintained at a high standard and to ensure our zero waste to landfill commitment is achieved. Safety, quality and environmental management systems at the SRS site and its downstream recycling partners are of upmost importance to Fuji Xerox Australia.

In 16/17 we are looking to enhance provisions for regional dealerships to return e-waste via TechCollect to ensure that the best environmental outcomes are achieved.

Remanufacturing at Rosehill

Remanufacturing at Rosehill grew markedly in the 14/15 and 15/16 years, backing up positive growth since 11/12. The growth has come out of a focus on research and development in new machine models and machine sales experiencing growth in print volume particularly in the Office colour market. The team at Rosehill launched 26 new remanufactured products into the Fuji Xerox Australia fleet over 14/15 and 15/16. Items remanufactured in Australia grew by 56 percent since our last sustainability report in 2014.

The mass of material remanufactured was 349 tonnes in 14/15, 393 tonnes in 15/16, up from 280 tonnes in 13/14.

Toner use optimisation project

In 13/14 a project was initiated to focus on driving down toner left in toner cartridges in Fuji Xerox’s most popular office colour multifunction devices by improving the operational effectiveness of the machines.

Toner manufacture is known to be one of the most energy intensive components of the print process and leads to the most emissions through the full lifecycle of the machine. Studies have shown that typically 6 kilograms of carbon is emitted per kilogram of toner produced. Ensuring that toner is effectively utilised by customers ensures that environmental impacts are reduced in the logistics network and in manufacturing of toner.

One of the key initiatives of the project was modifying the machine alert settings. Development of a reporting system allowed monitoring of device usage at a site level to identify high wastage. The reporting system was piloted with a ‘big four’ banking customer and has since been released to over 100 sites. This saw a reduction in waste toner by 21 percent in 13/14, a net toner saving of 10.8 tonnes, a further 32 percent reduction in 14/15, equating to 12.9 tonnes, and a further 3 percent reduction, 0.9 tonnes in 15/16. After 3 years of the project we have seen an 11 percent reduction in toner cartridge distribution into the market. For our customers this translates to an extra 1,067 million black and white prints and 173 million colour pages.





Reduction in toner wastage

toner

Electricity use at our Eco Manufacturing Centre

Although production volumes have continued to grow significantly, electricity use has fallen 5.5 percent, a 33 percent reduction per part produced. Since our Eco Manufacturing Centre was relocated from Zetland to our Rosehill facility in 2011, and subsequently certified 5 Star Green Star for the office interior in 2014, electricity use has fallen 66 percent when compared to the last full year of operation at the Zetland site. The team at Rosehill have implemented a number of projects to reduce power use since the move. These including upgrading warehouse lights to LED, reducing compressed air line pressure, switching off air conditioning earlier and adjustments to lighting controls. Our goal is to save a further 5 percent of electricity per part produced in 16/17.

Eliminating waste to landfill at our Eco Manufacturing Centre

Landfill from our Rosehill facility decreased 16 percent from 13/14, despite significant growth of remanufacturing activity. The site is ISO14001 certified, which encourages and supports continuous improvement. When compared to parts produced, the landfill produced by the site has decreased by 25 percent in 14/15 and 26 percent in 15/16. It has reduced 83 percent compared to the last full year of operation at the Zetland site, in 10/11, for landfill per part produced. This is attributable to the ongoing focus on material separation and the introduction of recycling for mixed films with new recycling partner Plastics Forests, and recycling of metallised films at Close the Loop.

  • Outlook for product stewardship
  • Optimise business and environmental outcomes from end-of-life resource recovery.
14/15 objectives   How did we do?
 Maintain the 13/14 quantity of parts remanufactured for reuse.  Met–Remanufactured units up 33 percent.
 Maintain our obligations under the Product Stewardship Act 2011 and associated regulations.  Met–We continue to meet our equipment recycling liable tonnage requirements.
 Achieve zero landfill commitment for all materials collected from our customers.  Met–Resource recovery was 99.7 percent.Met–Resource recovery was 99.7 percent.
 Reduce Eco Manufacturing Centre landfill by 10 percent per part produced.  Met–Achieved 25 percent reduction on a per part basis.
 Reduce Eco Manufacturing Centre electricity use by 10 percent per part produced.  Met–Achieved 28 percent reduction on a per part basis.
 15/16 objectives  How did we do?
 Maintain the 14/15 quantity of parts remanufactured for reuse.  Met–Remanufactured units up 17 percent.
 Maintain our obligations under the Product Stewardship Act 2011 and associated regulations.  Met–We continue to meet our equipment recycling liable tonnage requirements.
 Achieve zero landfill commitment for all materials collected from our customers.  Met–Resource recovery was 99.8 percent.
 Reduce Rosehill site landfill by 10 percent per part produced.  Met–Achieved 26 percent reduction on a per part basis.
 Reduce Rosehill site electricity use by 10 percent per part produced.  Met–Achieved 13 percent reduction on a per part basis.
 16/17 objectives  
 Reporting on consumables recycling made available for all Fuji Xerox Australia metropolitan customers.
Maintain zero waste to landfill goal from materials collected from customers.
 Meet Product Stewardship liable tonnage requirements for equipment recycling.
 Implement full coverage model for Fuji Xerox Australia’s dealership network for equipment recycling.
 Optimise road freight logistics for equipment recycling, reducing kilometres per kilogram travelled by 5 percent.
 Maintain 15/16 quantity of remanufactured parts.
 Reduce Rosehill site landfill by 10 percent per part produced.
 Reduce Rosehill site electricity consumption by 10 percent per part produced.
 1Fuji Xerox Co Ltd defines zero waste to landfill as a recycling rate of more than 99.5 percent