Formica Corporation
As an environmentally responsible company, Formica Corporation has established active programs in numerous areas of environmental management and will continue to make changes throughout its operations. These initiatives reflect management's belief that significant action must follow good intentions and ambitious goals if we are to be good global citizens.
The information provided here summarizes the activities of Formica Corporation in the spheres of raw material management, solid waste management and air pollution control, as well as steps we are taking to reduce consumption of non-renewable sources of energy. By focusing on these areas, Formica Corporation is able to be more efficient and cut costs - becoming a better company, as well as taking better care of our environment.
Formica Corporation's participation in the GreenGuard® program and LEED® program, and support for the Sustainable Forest Initiative®, form the foundation of our efforts to build a sustainable and responsible company.
Sustainable Forest Initiative
The filler paper used in Formica Brand Laminates is provided by a company that is third party certified to the Sustainable Forest Initiative.
GreenGuard Environmental Institute
Formica Solid Surfacing, Stone and high-pressure decorative laminate (HPDL) are GreenGuard Indoor Air Quality Certified under the GreenGuard Standard for Low-Emitting Products.
LEED (Leadership in Energy and Environmental Design) Rating System
Formica has instituted design and manufacturing standards that ensure its products contribute points to fulfill the U.S. Green Building Council's LEED rating system. In support of conservation and green buildings, we provide information about our products.
Governmental Environmental Regulations
Formica plants worldwide comply with all relevant local, state or provincial, and country governmental environmental regulations encompassing air emissions and quality, noise level, water discharges, and liquid and solid waste disposal.
Formica Corporation and Fletcher Building Group
On July 2, 2007, Formica Corporation was acquired by Fletcher Building Group, one of New Zealand's largest businesses. Together with the Laminex Group, Formica forms the Laminates & Panels division of Fletcher Building, but continues to operate as a separate business. Formica Corporation and Fletcher Building enjoy a similar culture which values ethical business practices, teamwork and responsible leadership. Both are focused on initiatives to reduce environmental impact and are active participants in "green" organizations. Fletcher Building is a member of both the New Zealand and Australia Green Building Councils and participates in the New Zealand Business Council for Sustainable Development.
Fletcher Building Takes Part in Voluntary Carbon
Disclosure Project for 2nd Year The Carbon Disclosure Project (CDP) represents a large group of institutional investors. Its purpose is to provide information to investors about the implications of climate change to shareholder value and commercial operations. Each year, the CDP collects information from companies about how they are preparing for climate change and reports this publicly. Refer to www.cdproject.net for more information.
Fletcher Building has participated in the CDP annual disclosure process for the second time this year. While all NZX50 and ASX100 companies are asked to participate, last year Fletcher Building was one of only a few NZX 50 companies that responded. While it is voluntary at this stage, Fletcher Building is keen to be proactive in its approach to the risks and opportunities associated with carbon emissions and climate change. A copy of the most recent report submitted by Fletcher Building is available on FBinfo. This year, for the first time, the data will be independently verified by PriceWaterhouseCoopers.
Future requirements for reporting
Carbon reporting is moving towards being a mandatory requirement for future government policies such as Australia's Energy Efficiency Opportunities program, and the proposals in both New Zealand and Australia for Emissions Trading. Fletcher Building will be required to collect more detailed data and to verify all energy use to a higher standard than currently. The Fletcher Building Board now requires 6-monthly reporting on carbon emissions so it is important for business units to keep complete, easily accessible records of energy use and expenditure.
Fletcher Building Facts & figures
Total emissions for the 2006 calendar year: 1,250,446 tons of CO2. (This includes the CO2 emitted during the generation of electricity used by Fletcher Building)
Total emissions in New Zealand: 817,954 tons
Total emissions in Australia: 432,491 tons
Total energy use: 12.53 PetaJoules (A Petajoule is about 20,000 tons of oil, or all the electricity used in a city of 45,000 people in a year)
% of electricity purchased from renewable sources: 41%*
Largest single emitter: Golden Bay Cement plant in NZ (520,583 tons in 2006)
The Pacific Steel and Wire plants emitted 103,797 tons
The 11 major manufacturing plants for panels/laminates located in both New Zealand and Australia emitted a total of 362,652 tons
What is Fletcher Building doing to contribute to the reduction of greenhouse gas emissions?
Reduction Programs
A range of reduction initiatives are being explored by business units. Recent examples include:
The upgraded Golden Bay Cement plant at Portland is achieving significant energy savings, as well as a huge reduction in dust emissions.
A new biomass fired wood drier at Dardanup particleboard plant designed for improved energy efficiency, increased biomass energy in place of natural gas and improved air emissions.
A new biomass furnace at Gympie MDF plant (approved) designed for improved energy efficiency from the biomass fuel, and secure energy supply.
A new glass furnace at Fletcher Insulation glass wool plant at Rooty Hill designed for improved energy efficiency.
Product Solutions
Fletcher Building businesses units have a range of products and building solutions that will improve the energy efficiency and comfort of buildings including:
Translucent roof sheeting that allows over 60% visible light transmission.
A steel and concrete floor system that enables suspended floors.
Designs for greater use of concrete in houses, improving heat retention and comfort.
Building solutions involving concrete, plasterboard and fiberglass insulation that improve heat retention and other performance attributes.
Development of low (formaldehyde) emission composite wood panels to provide improved indoor air quality.
As a builder of houses and commercial buildings , Fletcher Building is also gaining significant experience in construction methods that reduce the energy use of buildings.
Recycling and Re-Use
Fletcher Building operations contribute to reduced greenhouse gas emissions within the building and infrastructure sectors through the use of what would otherwise be materials sent to landfill. Examples are (figures are for annual use):
Pacific Steel uses over 200,000 tons of scrap steel in the electric arc furnace. The electric arc furnace process used to produce steel from scrap is significantly less energy and CO2 intensive than the integrated process required when using iron ore as raw material. The high proportion of electricity generated from renewable sources in New Zealand further decreases the CO2 emissions resulting from steel manufacture at this plant.
The Laminex Group in New Zealand uses 170,000 green tons of biomass waste as raw material in the manufacture of its panels. This biomass waste would otherwise generate CO2/methane emissions from landfills. It is the only composite wood panel manufacturer in New Zealand to develop the manufacturing processes required to utilize such volumes of biomass wood waste. It has also developed a unique technology that enables the use of a significant proportion of sawdust in the manufacture of medium density fibreboard.
The products manufactured by The Laminex Group result in a net storage of approximately 175,000 tons of CO2. Of this amount approximately 100,000 tons can be attributed to the CO2 stored in products manufactured from waste fiber.
The Laminex Group also uses 0.25 PetaJoules of renewable energy in New Zealand and more than 1.3 PetaJoules of renewable energy in its Australian panel plants.
Golden Bay Cement uses flyash as a supplementary cementitious raw material, and biomass as a supplementary fuel. The cement kiln has capability for converting a variety of other waste streams to energy.
Fletcher Aluminum uses over 4,000 tons of aluminum scrap in an aluminum remelt furnace. This scrap is sourced both from internally generated scrap (from the extrusion manufacturing process) and externally sourced scrap, primarily from competing aluminum extruders that do not have their own remelt facilities. Without this remelt facility this scrap would be destined for overseas markets or would require transport to the Comalco operation in Bluff. The remelt process used to produce aluminum from scrap is significantly less energy and CO2 intensive than the integrated process required using bauxite ore as raw material.
Tasman Insulation derives 80% of the glass required for manufacture of glasswool insulation products from recycled glass.
Industry Leadership & Membership
In 2002 Fletcher Building initiated Beacon Pathway - a research consortium formed to deliver knowledge and new products that will reduce the environmental impacts and energy use of houses while providing improved comfort and lower costs. (www.beaconpathway.co.nz)
Fletcher Building is an active member of both the Australian and New Zealand Green Building Councils. (www.nzgbc.org.nz and www.gbcaus.org)
Fletcher Building is participating in the New Zealand Business Council for Sustainable Development project to identify the most effective means to develop a more sustainable built environment. (www.nzbcsd.org.nz)
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