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the only innovation that we understand is sustainable innovation.
We are convinced that our approach to sustainability in business is the best choice to make to continue the success that has allowed us to become what we are today. Marco Checchi, CEO
packaging must be beautiful, intelligent and responsible.
To ensure the best products for clients and consumers, all our production plants have progressively adhered to ever-more demanding international standards in terms of quality, food safety, environment and compliance with norms applicable to products for food storage.
we took away the PVC and added safety.
We were among the first producers to develop crown corks with PVC-free liner at the beginning of the 90s and we continue to lead the market of caps used for packaging food in this direction in collaboration with our suppliers and partners. Among the various innovations, we are developing this technology of PVC-free caps for baby food containers.
using energy wisely and reducing emissions into the atmosphere.
“The research and development applied to our production processes has an important role in this sector.”
We invest resources to improve energy efficiency in our production processes and to minimize emissions into the atmosphere.
With respect to the past, our production plants are more spacious and efficient and the continuous improvement of these processes has been pursued thanks both to our people's ideas and to specific investments in new technologies. The research and development applied to our production processes has an important role in this sector.
raw materials and recycled materials
“Steel and Aluminium are infinitely recyclable materials”
The main raw materials we use for the production of our caps is metal (steel and Aluminium) that we use in the shape of sheets that are varnished, lithographed and then converted into caps and capsules. Metal is a global product, infinitely recyclable without loss of quality and is purchased by the best manufacturers all over the world. In Europe and all over the world, the majority of packaging materials are recovered as metal (steel and Aluminium) at the end of their life cycle and return into the industrial production cycle: the separate collection of domestic waste and the recovery of industrial waste means less consumption of enormous quantities of natural resources (energy and raw materials). This same philosophy is applied to packaging materials: half of the weight of carton containers are made of recycled materials and, where possible from a logistics point of view, reusable metal containers are also available, even the foldable type to optimize transportation during the recovery phase. Even an ever greater quantity of wooden pallets, like EPAL, CHEP, LPR, are recyclable. The recovery of raw materials actively continues within our plants: almost all the waste produced is collected separately and brought to qualified waste management suppliers to put it back into the recycling process whenever possible. The majority in weight is made up of metal (steel and Aluminium), but other materials like plastic, paper and wood are also important.
Total amount of steel packaging on the market in 2013 Total tonnes collected Total tonnes sent to recycling Percentage sent to recycling of total released on market
435.149 435.149 320.231 73,600%
the new metal recycles brand
Metal Recycles Forever was created to group together different environmental messages regarding metal packaging in Europe into one symbol. This brand is a new, highly-valuable instrument in that it allows companies to convey how to recycle their products and the advantages of doing it with a simple message. 'Infinite recycling' is also an important invitation for the consumer who is ever more respectful of the environment.
our waste is mainly composed of metal deriving from the process of cutting sheets into shells.
“in 2013 we had more than 95% of our waste recycled”
Approximately 10% of the sheet is not used in the final product and therefore ends up as scrap from the production process which represents a huge environmental value if recovered. Even plastic materials mostly derive from the process of extrusion and application of the liner and may be recycled and reused for purposes not related to food. Paper, cardboard and wood from packaging material are reused in the sector of paper recycling. Finally, a limited quantity of hazardous waste, such as from coatings and ink residues, machine lubricants, used light bulbs and used printer cartridges, is disposed of under highly controlled conditions and in complete compliance with applicable norms. This waste is categorised internally and collected separately and given to authorised, external companies that are environment-friendly. In recent years we have had more than 95% of our waste recycled.
Chart featuring our raw materials purchase per type//
Type of material 2011 (kg) 2012 (kg) 2013 (kg)
Steel (tin and chrome plate, stainless steel) 51.289.637 58.557.254 55.306.706
Aluminium 1.764.837 2.308.674 1.994.912
Paint products (coatings, enamels, inks and solvents) 1.703.609 1.717.680 1.617.871
Plastic materials (cap, liners and bodies) 8.783.243 7.124.606 6.212.577
Packaging materials 2.909.502 2.874.595 3.022.110
the intermodal transport of goods is an economically sustainable solution with reduced environmental impact.
“In 2011-2012-2013 we cut CO2 emissions by a total of more than 1000 tonnes thanks to intermodal transport.”
The transfer of large quantities of goods from land to rail transport and also sea transport has positive effects on energy consumption and CO2 emissions and other exhaust gases produced by traditional land transport. For this reason, we are continuously on the look-out for opportunities to increase the volume of the products which are transported using combined means of transport (land, rail, river and sea) for delivery to clients. Thanks to intermodal transport we cut CO2 emissions by over 1000 tonnes in the years 2011-2012-2013.
Two examples of intermodal transport//
Bulmers Limited Ireland (Atessa - Clonmel) Heineken - The Netherlands (Atessa - Zoeterwoude)
Over 2000 km by train and ship Over 800 km by train
Following an initial part of the journey by land to reach the Novara train station, the swap body is loaded onto the train which takes it to Rotterdam covering a distance of over 1000 km. Then, from the port of Rotterdam there is another 1100 km journey by sea to reach the port of Waterford, only 50 km from the Bulmers plant in Clonmel-Tipperary. Following an initial part of the journey by land to reach the Gallarate (MI) train station, the swap body is loaded onto the train which takes it to Antwerp or D?sseldorf covering a distance of over 800 km. Then, after having covered 150 km on land, it reaches the Heineken plant in Zoeterwoude.
In 2013 we launched the "all you need is less" campaign, which allowed us to sell over 2 billion "smart crown" caps.
The Smart Crown caps equal a cut of more than 15% of CO2 emissions without altering performance. In 2013 this allowed us to reduce CO2 emissions by over 3000 tonnes and the trend of this product is on the rise for the future.
2010 - 2011 Pre-series production, a few million caps for sampling and start-up approval tests for clients.
2012 Industrialisation: over 400 million crown corks.
2013 Expansion and consolidation with over 2 billion units
2014 New market standard on over 4 billion units produced
Emilia, scientific research and our love for culture and sport.
Total investments for the community in different areas//
Besides scientific research, we support social, cultural and artistic projects and activities which constitute fundamental society values and contribute to improving the quality of life of the local communities where we operate.
We support various local sports associations which our own staff is a part of with the goal of giving back value to the region in terms of community well-being. Each year we allocate an average of over 2% of our EBIT to different projects in favour of the community.
summary of sustainability report data