Unilever announced today that all its factories across Europe have joined those in North America in achieving zero non-hazardous waste to landfill.

Under the Unilever Sustainable Living Plan, by 2020 total waste sent for disposal will be below 2008 levels, despite growing the business significantly. Achieving zero non-hazardous waste from factories is a key element of this target. The achievement to date has been made possible with minimal need for capital expenditure and has avoided cumulative disposal costs of more than €17 million. On 28 April this year, the Unilever Sustainable Living Report 2013 will be published, and it will confirm that Unilever has reduced total waste sent for disposal by 66% per tonne of production since 2008.

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Pier Luigi Sigismondi, Unilever Chief Supply Chain Officer, said: “We have seen a rapid acceleration in converting the network to zero waste. In 2010, 52 sites were there. We have now reached 200 sites. We are on track to hit our revised target of 100% of sites by 2015, five years ahead of the original 2020 target. I am proud of the team effort which has got us to this milestone.”

Sigismondi added that a focus on eliminating waste from manufacturing processes in North America, Europe, the majority of Latin America and a number of other countries has brought the final goal firmly in sight, adding that two key factors could be identified for this success:

1. Reducing waste at source was identified early on as a game changer when the campaign began in 2010.

100% Zero Non-Hazardous Waste to Landfill has been achieved at all European sites through the application of the “three Rs” principle: reduce, reuse and recycle. Where solid waste cannot be eliminated, reused or recycled, it is sent for energy recovery instead of to a landfill. Some examples include:

St Dizier, France – ice cream waste separated from packaging via a screw compressor, and passed on to create biogas. This resulted in a saving of €50, 000 per annum.

Leeds, UK – upgraded the Effluent Treatment Plant so that they could send over 1,000 tonnes of effluent to be used as a fertiliser for professional football pitch turf, saving over £35, 000 per annum.

2. Creating a mindset for change across the entire network.

Unilever’s Tortuguitas site in Argentina was the second largest waste generating site in the company, yet the factory leadership team remained convinced they could achieve their target of sending zero non-hazardous waste to landfill in 2013.

Working with managers across the site, the Factory Director helped create a zero mindset which spread across the entire factory encouraging them to reach their goal. They formed “Green Teams” – groups of employees given specific responsibility for generating eco-efficiency ideas and creating projects to eliminate and reduce waste generation.

The zero mindset rapidly spread across Tortuguitas to encompass the way the site works with local suppliers. Supported by the unique Global CapEx fund “Small Action Big Difference” for sustainability projects, the Argentinean team developed product recovery equipment on their production lines This project alone has resulted in 88 tonnes per year of recovered product and €35,000 costs avoided, all within a one year payback period.

The intention now is to spread this knowledge across the remaining factories. The Environmental Coordinator from the Africa cluster has recently visited Tortuguitas to learn about the best practices. This knowledge will then be used to help make the necessary changes in helping all African factories achieve zero non-hazardous waste to landfill.

Source: Unilever