Our performance on reducing wastes disposed from manufacturing sites has significantly exceeded our expectations against our 2020 target. For this reason, in 2012 we introduced a more stretching target - increasing the scale of our ambition (zero disposed non-hazardous waste). We are already well on the way to achieving this.
75% (186) of our manufacturing sites disposed of zero non-hazardous waste to landfill by the end of 2013 - an increase of more than 50 sites during the year. Our North American manufacturing team were the first operating region to achieve this milestone at all sites. At the end of 2013 both Europe and Latin America were also very close to achieving this goal too. All manufacturing sites in 38 countries now dispose of zero non-hazardous waste to landfill.
The scale and speed of reduction of disposed waste has been achieved by deploying best practice everywhere and through developing business partnerships with our waste suppliers that draw on the expertise that we collectively possess. These improvements have been driven by clear sponsorship and commitment of our senior leadership team and our employees.
A small number of sites contribute significantly to our remaining disposed waste footprint. During 2013 we focused our efforts in supporting these sites to reduce waste at source, segregate waste streams and to identify cost effective waste management routes to recycle and recover materials. The Zero Non-Hazardous Waste to Landfill programme has been a major contributing factor in reducing our total waste by making sites more aware of their waste streams and identifying opportunities to eliminate and reduce wastes at source.
Our significant achievements with non-hazardous wastes have also driven a reduction in disposed hazardous wastes which have in turn reduced by an even greater proportion. The relatively small quantity of hazardous wastes generated by our manufacturing sites (approximately 3% of our disposed waste footprint) are not included in our Zero Waste to Landfill target due to legal controls in some countries which specify their end-of-life treatment.
Finding new uses for waste
In manufacturing, apart from eliminating waste, we also employ three other means of cutting our waste - reuse, recycling and recovery. Examples include: the introduction of reusable transit packaging in our Hefei factory in China; waste mayonnaise converted to biofuel; and effluent plant sludges in Turkey and the Philippines given a second life as alternative raw materials in construction products.
Our targets commit us to maintaining our 2008 levels of greenhouse gas, water and waste impacts against a backdrop of significant growth in our business. To build a detailed plan to achieve this, we reviewed the likely areas of growth from a geographic and product perspective. We also looked at the current environmental performance of all our sites.
As a result we identified a number of '‘levers’' or areas of potential change which will deliver reductions in our environmental impact, including waste. We asked all our manufacturing sites to assess themselves against these levers, which showed us where the opportunities for reductions lie. Projects have been identified by individual sites which, when implemented, will further reduce waste.
We are also extending our World Class Manufacturing programme, which sets a global benchmark for the reduction of waste and cost. By 2014, almost half our total production costs will be from sites within this programme.
Progress on reducing waste from manufacturing
In 2013 we further reduced waste disposed from manufacturing sites by 30% compared to the previous year. Disposed wastes are now approximately 97,000 tonnes or 66%† lower per tonne of production than in our 2008 baseline year.
This significant achievement - which has far exceeded our initial target - was achieved through waste elimination and reduction activities and by diverting waste away from disposal routes such as landfill.
In 2013 we achieved our highest ever recycling rate with approximately 94% of operational waste being reused, recycled or recovered.