OUR CARBON FOOTPRINT
Our electricity consumption comes from biomass. Compared to the purchase of green electricity, this indicates an increase in carbon emissions. We managed the limits in carbon emissions by reducing the capacity of our biomass-installation and by ‘greening’ our carfleet
energy conservation measures
2015: Active monitoring programme to reduce compressed air system leaks
Replacement of insulation and outer walls
Heat exchangers applied in painting section
Electrical forklifts used in the warehouse
Partial LED lighting applied in and around factory
Motion sensors applied to lighting=system
2016: Demand-driven dust exhaust systems
2017: Investment in high efficiency energy conserving IE-4 motors for compressor and exhaust ventilation systems
Optimizing of compressor system and controls
2018: New packing machine
2019: Introducing circulair kitchen, product development according to CSR principes, from waste stream to value stream.
2020: Renovation roof The Kitchen Factory Roof, insulation The Kitchen Factory, From 1500 solar panels to 8000 solar panels, Realization green kitchen concept
Marc Luijkx, technical service manager
‘For years we have been busy implementing energy conservation measures in our factory. During the procurement phase for new machinery sustainability and energy consumption play a big role.’
IE4-motors for compressed air supply
DKG Group opts for IE4 motors in the field of compressed air supply. These are maintenance-friendly and energy efficient motors. Compressed air is used, among other things, for the moving of machine parts.
More than 90% of the machine park uses compressed air.
Over 65% of the industrial energy consumption comes from electric drives. The IE4 motors are classified in the highest efficiency class.
By choosing IE4 motors, DKG Group gives a clear signal how important it considers it to reduce CO2 emissions. DKG Group is able to realize an energy saving of 3 to 10% with the new IE4 motors.
DKG Group is able to realize an energy saving of 3 to 10% with the new IE4 motors.
note: as of 01-01-2017, motors with a nominal capacity of 0.75 to 375 kW must meet the requirements of the IE3 efficiency level.
Solar panels & Biomass installation
Since 2014 there are 2,300m2 of solar panels on the roof of the kitchen factory. These panels generate 350,000 kWh per year.
In 2020, the vast majority of the factory’s roof has been renovated, insulated and also fitted with solar panels. With a total of 8,000 solar panels we generate about 25-30% of our annual electricity consumption.
Our factory is heated by incinerating our smaller sawing waste. By insulating the roof, the biomass installation runs at lower power, the excess wood waste is returned to the chipboard industry in order to make new chipboard
85% ENERGy SAVINGS BECAUSE OF NEW PACKAGING LINE
To facilitate the packaging of thousands of parts per week, the Kitchen Factory has access to two new packaging machines since Q3 2018. This means that we say goodbye to our shrink furnaces and one of the wrapping machines.
The energy consumption decreases by 85% compared to the current shrink furnaces. In addition, cardboard is more environmentally friendly than the current packaging materials.
sustainable laser chamfering
We have implemented laser chamfering in the production phase of our kitchens. By doing so we have removed glue from the chamfering process. Additionally, this modern production technique removes the need for the glue to be raised and kept at higher temperatures. This means additional energy savings. Additionally, the chamfers have increased resistance to both fluids and heat, increasing the lifespan of our kitchens.
environmentally friendly materials
In our painting section we exclusively use water based paint. This is better for the environment, as well as our employees.
Our Greenpanel® countertops are FSC® certified and production of these panels emits 57% less CO2. Since this year the production of countertops for Keller Kitchens has even turned climate neutral. Additionally, the materials used are biodegradable and fully recyclable.
We advise our customers to implement LED lighting, water conserving faucets and high efficiency electrical kitchen equipment into their kitchens.
quality and environmental certificates
In 2018 we aim to have both our ISO 9001 and ISO 14001 certificates.
We have mapped the environmental impact of the circular kitchen by producing a chain analysis. The chain analysis shows that:
- the circular kitchen has 25.46 kg less carbon emissions in the 2nd life cycle compared to a linear kitchen;
- the chain emissions of 100 linear kitchens equals to 122,14 circular kitchens;
- the chain emissions of eight 45m3 city trailers with linear kitchens equals to 10 city trailers with circular kitchens.
Keller kitchens had a vision of the kitchen of the future
Our green kitchen concept cinsists of 4 themes:
- The function of the kitchen: from traditional cooking to part of the enjoyment of living
- Megatrend in food: the demand for fresh and local increases
- Inefficient: the current kitchen space is wasteful, such as water waste and food spoilage
- Circularity raw materials: we want to market a kitchen that is made entirely of circular materials
Our largest waste stream is wood (64%). To mitigate this waste stream, we burn residual cutting waste in our biomass installation. Part of the wood that can no longer be used for the production of new kitchens is reused as input for the particleboard industry. Any waste that is not reused through these avenues is adequately handled by our waste partner Suez.
improving waste separation
An ever-increasing part of waste can be reused as input material for other processes. We aim to further reduce the segment of our waste that cannot be reused (currently 19%). Additionally we have started improving our waste separation in the factory, the canteen, and the offices.
Following the circular kitchen, we have now also been able to set up a circular flow with the chipboard waste that we no longer need ourselves.
Instead of being disposed of via a special waste processor, our chipboard is now collected by our chipboard supplier. The idea behind this is that we deal with our waste in the most sustainable way possible, with waste chipboard serving as the raw material for a new chipboard.
Reusing wood waste
In the final months of 2016 the DKG kitchen factory has started the “Hout met een fout” (Wood with a flaw) project. In this project we repurpose large flawed wood segments into smaller panels or cabinet parts. By doing so, material that was previously considered waste is reused in our kitchens. During the first 16 weeks we have repurposed 77.000 kilograms of particleboard/MDF. By doing so we have effectively reduced our waste stream to half of the original volume.
Bas van Hoof
‘Many of the activities that have been ongoing for years, often intrinsically motivated, or motivated by environmental or cost reductions, can now be adequately structured in the CSR projects.