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We’re

cutting

carbs

with carla

Our carbon
footprint that is!

This is Carla. She works at Ball. Together we strive to get in shape by 2020 by cutting the carbon footprint of our beverage cans by 25%.

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Carla's Diary Cover

Carla’s
Carbon
Chronicle

2010-2020

Carla’s carbon chronicle

This is

Carla

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Ball strives to reduce the carbon footprint of its most common beverage can formats by one-fourth, a program known as Cut/4 CArboN (2010-2020).

Carla works at Ball and was hired as Ball’s Carbon Cutting Coach.

In support of Ball’s carbon cutting efforts, Carla has created the Carbon Chronicles as a means to track the overall progress made in the areas of innovation, operations, recycling and the overall supply chain.

Cut/4

Carbon

„Ball created its Cut/4 CArboN program because finding solutions to enhance the sustainability credentials of products throughout their value chain requires multidisciplinary perspectives, taking into account improvements from areas such as innovation, supply chain, recycling and operational excellence,”
Bjoern Kulmann Sustainability Director at Ball

 

By 2020, we strive to cut the carbon footprint of our beverage cans by one-fourth

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Ball is committed to reducing the carbon footprint of our most common beverage can formats per region by 10 percent from 2010 to 2020 through efforts that are in our control, such as optimizing the weight of our cans and our plants’ energy efficiency.

Combined with the efforts of industry partners, like our suppliers and customers, to increase beverage can recycling rates as well as to reduce the energy intensity of aluminum production along the supply chain, we expect the carbon footprint of our beverage cans to be reduced by 25 percent by 2020.

To learn more about Ball and its Cut/4 CArboN campaign, please visit www.ball.com/cut-4-carbon/

Energy Efficiency

Energy Efficiency

 
Braunschweig, Germany

 As much as 80-90 percent of electrical energy used by industrial air compressors converts into heat. This thermal energy can be recovered and put to good use.

That’s why Ball installed a system for heat recovery from compressors and connected this to the plant office heating system in Braunschweig (Germany). This saves 250.000 kWh of hot water.

Ball insulated the washer of line 1 in its Serbian plant in Belgrade. Stage 1, 2, 4 baths have also been insulated with stone wool. What does this mean for Belgrade? 200.000 kWh of gas saved!

 

A low pressure net was connected to 23 bodymakers in the plant in Bierne, France, translating to 210.000 kWh of saved electricity.

 

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Energy Efficiency

Energy Efficiency

Braunschweig, Germany

Sometimes even the simplest of measures can help. By replacing the lighting in Braunschweig’s (Germany) truck loading bay, where  Ball warehouses its coils and ends, a 40.000 kWh savings of electricity is realized.

Deeside_scrap-system
Deeside, UK

Ball examines even the most minute of details during the production process. Optimizing the scrap handling system pays off, with Deeside, UK realizing a savings in electricity of 300.000 kWh.

Energy Efficiency

Energy Efficiency

Gas savings in the south of France

la Ciotat, France

The insulation of the washer oven in both lines in La Ciotat results in 700.000 kWh of gas saved. The savings however doesn’t stop there, as another 100.000 kWh of gas is recovered by the insulation of the coolant piping.

…as well as in the Netherlands

OSS, NETHERLANDS
OSS, NETHERLANDS

In Ball’s Dutch plant in Oss, the conversion of a steel mat to kevlar for Line 2 saves up to 693.400 kWh of gas.

Energy Efficiency

Energy Efficiency

 

Ball replaces two spencer turbine vacuum blowers with more efficient blowers in Ft. Atkinson, Wisconsin. This amounts to 128.908 kWh of electricity and 87.915 kWh of gas savings. 

Fort Atkinson, Wisconsin
Ft. Atkinson, Wisconsin

Further to the south, the installation of a low pressure compressor and piping system in Jacarei, Brazil translates to 300.000 kWh of electricity savings.

Rome, GeorgiA

Rome, GA

Replacing all interior lighting in Rome, Georgia improves the plant’s electric efficiency by 7.8 percent

Recycling

Recycling

Because…Every Can Counts:

France’s sister program – Chaque Cannette Compte – launches.

 

2010 also finds Ball partnering with TAFISA (The Association for International Sport for All) in Poland, who together promote mass sports while simultaneously strengthening their commitment to the environment and recycling.

can_crusher

Every Can Counts (2009) aims to enable and encourage more people to recycle the drink cans they use outside the home. Developed by the beverage can manufacturing and recycling industry in 2009, there are now eight Every Can Counts programmes operating across Europe, with more due to launch in the near future. Countries of operation: Ireland, UK, France, Austria, Hungary, Montenegro, Romania, Greece. Ball is a founding member of this organization.

Energy Efficiency

Energy Efficiency

The replacement of old eddy current and DC motor drives in Radomonsko, Poland to standard 3 phase motors with variable frequency drives (both lines), leads to 362.500 kWh of electricity saved.

 Mariusz Makowski, Electrician

Radomsko, Poland
Radomsko, Poland
Weight Optimization

Weight Optimization

Convenience is King!

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The Handy Can is not only a great new can format but Ball has also reduced the weight of this 25cl can by 1.7 percent .

 

                                                                                                                            Carla with megaphone

 

 

 

 

 

 
Recycling

Recycling

backi petrovac, Serbia

Wrexham, UK

This year, Every Can Counts UK collects 51 million cans.

Supply Chain

Supply Chain

Bierne, France

Bierne, France

New jumbo trucks in Bierne, France leads to a decrease of transport to a nearby customers by over 1.000 kilometers per year.

Improving the Supply Chain the “SmartWay”  

smart way logo

The purpose of the SmartWay program (Ball is a member since 2009) is to improve fuel efficiency and the environmental performance of goods moving through the supply chain.

 

Energy Efficiency

Energy Efficiency

Hermsdorf, Germany

Hermsdorf, Ger

In Hermsdorf, Germany the insulation of the washer baths result in 200.000 kWh of gas saved.

The UK plants are also saving energy

Rugby, UK

Rugby, UK

In Rugby,  lowering the temperature for clear base coat leads to 500.000 kWh of gas saved. In Wrexham, all fan motors are getting equipped with inverters which means 740.000 kWh of electricity saved.

Energy Efficiency

Energy Efficiency

Radomsko, Poland

How did Ball’s Radomsko plant accomplish 388.080 kWh of electricity savings? Replacement of the fan on the bodymaker/trimmer elevator on fourteen machines.

La Ciotat, France

La Ciotat, France, modifies two scrap extraction systems for cupper and bodymaker. The frequency of the motors was reduced from 50 to 45 hertz, amounting to an electrical savings of  301.600 kWh.

Weight Optimization

Weight Optimization

The New Generation of PackagingBall's CDL end
Ball’s CDL End

 

In 2012, Braunschweig, Germany converts a further can end line to the lighter CDL end. The CDL end weighs about 10% less than a conventional can end.

 

 
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Recycling

Recycling

Chaque Cannette Compte supports almost 200 events in 2012 to further increase consumer awareness around the benefits of recycling.

TAFISA

Ball and TAFISA partner with World Walking Day, an event whose main goal is to develop innovative concepts to connect sports with environmental protection. The design of the cans, distributed in 17 cities, promoted ecological behaviour while recal took care of the recycling of the empty packages.

Supply Chain

Supply Chain

Print

Small Number – Big Difference

In La Ciotat (France), an increase of the number of layers per pallet to be put into export containers leads to the accomodation of an additional 5 percent of cans into the same size container. This leads to a decrease of the number of shipments by 350 per year while still shipping the same amount of cans – almost one shipment each day!

 

 

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Energy Efficiency

Energy Efficiency

 

The replacement of HQL lamps with LED in the palletiser area in the production hall in Hermsdorf, Germany,  equals 159.600 kWh of electricity saved.

Belgrade, SeRBia

Belgrade, SRB

In Belgrade, Serbia, Ball takes a closer look at their compressors: the replacement of an absorption air dryer by a refrigerated results in 800.000 kWh of electricity savings.

Oss, Netherlands

Oss, Netherlands

Ball implements a control loop which measures the concentration of CO in Oss, Netherlands. By reducing the temperature settings from 820 to 780 degrees and adjusting the temperature accordingly, Oss saves 1.050.800 kWh of gas!

Weight Optimization

Weight Optimization

Time for Breakthrough Technology!

The B-Can launches in Europe – a new reduced weight format (5% material savings.) Offering the same brand promise as the standard can format, Ball ”engineered out the unnecessary” – a practice based not on what is technologically feasible but rather on what is actually needed to perform.

Ongoing Research makes the Difference

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At Ball, not only the standard can formats are a permanent object of research. The 44cl can, for example, that is produced in Rugby, UK, is now 2.6 percent lighter than the first version of it.

Recycling

Recycling

Every Can Counts

Chaque Cannette Compte has more than 670 individual sites using the services of the program and its partners.

Montenegro

Montenegro

During 537 events and 5710 projects, the recan foundation collected 6,247 kg of used beverage cans.

Supply Chain

Supply Chain

Alunimum

In 2013, Ball joins the Aluminium Stewardship Initiative (ASI), a program designed to develop a standard to foster responsible environmental, social and governance principles and performance throughout the aluminum value chain.

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Alcoa successfully saves 3.1 million metric tons of GHG emissions

Ball’s partner Alcoa reduces absolute GHG emissions by 3.1 million metric tons from 2012. Alcoa’s total 2013 GHG emissions (CO2 equivalents, or CO2e) equal 43.4 million metric tons, of which 28.2 million metric tons were direct emissions.

 

 

Energy Efficiency

Energy Efficiency

Bierne, France

Bierne, France

Ball brings its Bierne plant up to speed: The replacement of a vacuum pump and installation of variable frequency drives turn into 33.600 kWh of electricity savings.

 

Gas Savings in La Ciotat…

La Ciotat, France

La Ciotat, France

The reduction of the fresh air in-take from multiple air handling units amounts to 1.069.200 kWh of gas saved. Additionally, the replacement of printer ovens’ burners saves 588.000 kWh of gas.

Energy Efficiency

Energy Efficiency

 

 

 

Weissenthrum, Germany
Weissenthurm, Germany

New lighting installed in the warehouse in Ball’s Weissenthurm plant saves 294.000 kWh of electricity.

 

 

 

In Weissenthurm, Germany, Ball replaces the existing motors in the rooftop air handling units  saving 789.600 kWh of electricity.

 

The variable frequency drive (VFD) for a washer pump in Wrexham, UK, turns into a savings of 554.400 kWh of electricity.

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Recycling

Recycling

Kopaonik, Serbia

CanBasketGameKop2

“TAFISA Sport for All Ski Fest” in the Kopaonik Ski Resort: recan implements the eco-game by introducing can crushers as a means to communicate the value of recycling. Can crushers are now permanently positioned in resort.

Belgrade, Serbia

CCBicycleTafisa

TAFISA is not getting tired: During the Belgrade Bicycle Event, sponsored by Coca Cola, Recan is collecting cans with can crushers and boxes.

Recycling

Recycling

Montenegro

Montenegro

Limenko, the recycling mascot, teaches children why it is important to recycle. Kids that recycle five cans as part of the children’s theatre program are rewarded with an on-stage performance.

Every Can Counts Project launched at Sea Dance Festival in Montenegro.

Montenegro
Montenegro

As of 2014, MetalMatter’s campaigns have reached over 2.4 million households across the UK with new partnerships in tandem with local authorities planned through the rest of 2014, in an effort to increase consumer awareness around kerbside recycling.

Supply Chain

Supply Chain

Ball partner Novelis opens world’s largest aluminum recycling facility!

novelis 2

 

 Hydro

 

Our partner Hydro aims to emit 1.56 kg of CO2 equivalents from the electrolysis process for each kg of aluminium produced. By comparison, the company in 2009 emitted 1.85 kg for each kg of aluminium produced (minus 15.7%).

 

 

 

Recycling

Recycling

 

Great American Roundup Industry Challenge

Great American Can Roundup
Ball topped competition by collecting most pounds of cans

Ball employees recycled 88,473 pounds of aluminum cans and raised nearly 58,000 Dollars for local charities during this year’s Great American Can Roundup Industry Challenge.

 

Nearly 133,695 Dollars Raised for Charity

Great American Can Roundup
178,099 lbs of cans recycled

The Great American Can RoundUp Industry Challenge is sponsored by the Can Manufacturers Institute (CMI) and held annually to raise awareness of the environmental benefits of recycling cans. Participating American can manufacturers and aluminum suppliers engage their plant facilities to partner with local charities, schools and other organizations to collect and recycle used aluminum beverage cans. Proceeds from the recycled cans are then donated to a charity of the company’s choice.

Recycling

Recycling

 

Curbside Value Partnership's Recycling Partnership

The Curbside Value Partnership’s (CVP) Recycling Partnership is providing The City of Columbia, South Carolina with $300,000 to modernize its residential curbside recycling program. Ball’s collaborative effort with CVP is supporting the drive for increased material recovery and in turn, diverting millions of tons of permanent material away from landfills and back into the circular economy stream.

 

MetalMatters in Wrexham!
MetalMatters in Wrexham!

The MetalMatters’s campaign to increase household recycling rates of metal packaging is checking off another success.

UK local authority (LA) Wrexham County Borough Council has signed up to participate making this the 50th LA across the country to participate in delivering targeted messaging to residents about the benefits of recycling.

 

Energy Efficiency

Energy Efficiency

Wind Energy

 History is in the making at Ball with the Spring 2015 installation of renewable energy sources coming by way of three, new wind turbines. These 1.5 megawatt powerhouses will generate about 20% of the plants overall electrical needs. That equals an estimated annual CO2 savings of 9,221 metric tons.

“Ball is the sustainability leader in the North American packaging industry, and energy efficiency is one of our key sustainability goals,” said Glenn Jost, Ball’s Findlay plant manager. “This wind energy project is a win-win for sustainability, for the local community and for the company.”

Wind Turbine

 

Between 2010 and 2014, the Saratoga Springs plant improved its electrial and natural gas efficiency by more than 5 percent. Plant manager Bob Nelson and his committed team recognized that by recovering the heat from the closed loop cooling water system and reusing it for the incoming process makeup water, the plant was able to save a ‘cool’ 89.658 kWh in natural gas.

 

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Notable Progress Toward 10-Year Carbon Footprint Reduction Target

Ball makes first global announcement regarding progress towards 2020 Cut 4/CArboN target: results show a 10 percent improvement and the company on track to meet its 25% reduction goal.

“We developed our comprehensive Cut/4 CArboN program in order to demonstrate our contribution to our customers’ ambitious product carbon footprint reduction goals,” says Bjoern Kulmann, director sustainability at Ball Corporation. “We are pleased with the achievements we have made to date and have specific plans in place that will pave the way toward our 2020 target.”

Bjoern Kulmann

Bjoern Kulmann, Director Sustainability at Ball Corporation

 

Get in

touch with

carla

 

Ball Packaging Europe Holding GmbH & Co. KG

Business Center Europe
Georg-von-Boeselager-Straße 25

D – 53117 Bonn
Tel.: +49 (0) 228 50 216 -0

Carla

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Shape up with Ball!

iPhone App

Enjoy your very own Augmented Reality Moment with our Carbon Cutting Coach Carla by engaging your Smartphone or Tablet. Check it out!

1. Download Junaio App (click here for iPhone and here for Android)
2. Scan any Ball Logo (both on-screen and off)
3. Take fun pictures with Carla
4. Share pictures throughout your social media channels using #carlacutscarbs

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