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More Henkel Corporate Reporting 2014
Jordi Cruz (left), SHEQ Latin America Manager, and Jose Luis Romero Mejia, Sulfonation Operator, examine the new heat recovery system’s contribution to more efficient production in Toluca, Mexico.
Project Xina will double the capacity and reduce the environmental impact of our largest detergent production site in Latin America.
Project Xina, a 27 million euro expansion project named for a volcano near our Toluca production site, will double the production area, modernize technologies, and make logistics more efficient. Several upgrades were completed in 2014 and are already reducing the plant’s environmental footprint. For example, a new heat recovery system was installed to save energy. The new system uses waste heat from our sulfonation plant to preheat the air for spray-drying powder detergents.
We also introduced a two-step reverse osmosis process to reduce wastewater from our liquid detergent production and increase the yield of recycled water. With the first measures in place, annual energy consumption has decreased by 13 percent per ton of product, water consumption has decreased by 14 percent per ton of product, and waste generation has decreased by 19 percent per ton of product. The expansion has taken place without disrupting ongoing production and without a single lost-time accident in 2014. Additional efficiency gains are expected once all measures are fully implemented in 2015.
Once the project is complete, Toluca will be Henkel’s largest detergent production site outside of Düsseldorf and will enable us to produce powder and liquid detergents efficiently for the fast-growing Latin American market. The modern factory will also serve as a sustainability and safety benchmark for our entire group.
belonging to our three business units around the world are the foundation for our strong presence both in mature and emerging markets. Of these sites, five are located in Mexico.
is the sum we are investing to expand production areas, modernize technologies and make logistics more efficient at our laundry detergent production site in Toluca, Mexico.
is the record for the expansion of our laundry detergent site in Toluca in 2014. 89 percent of our worldwide production sites were accident-free last year.
The new heat-recovery system repurposes heat from our sulfonation plant (seen here) in order to pre-heat the air to be used our spray-drying production area. This is a good example of an efficient in-house process.
Maintenance Manager Fernando Rodriguez Guzman (left) and Maintenance Operator Claudio Delgadillo make a routine inspection of the heat exchangers in Toluca.
Gabriela Bautista, Liquid Production Supervisor, collects temperature and pressure data in the sulfonation plant.
The new boiler is automated to generate steam according to the needs of the plant. This reduces gas usage by 7 percent and water use by 30 percent.
Steam Boiler Operator Isidro Pilar Juarez (left) and Maintenance Manager Fernando Rodriguez Guzman discuss the new boiler’s performance.
Henkel operates 169 production sites worldwide. We work continuously at all of these sites to reduce energy and water use and waste generation while upholding our promise of quality and safety. We have set concrete targets for our production sites to help steer progress toward our long-term “Factor 3” goal. By the end of 2015, we aim to reduce our energy and water use and waste volume by 15 percent per production unit and reduce our worldwide accident rate by 20 percent (base year: 2010).
In 2014, we achieved all four of these targets ahead of schedule. Energy use per production unit has improved by 20 percent, water use per production unit by 19 percent and waste volume per production unit by 18 percent (22 percent without construction and demolition waste) versus 2010. We also improved our worldwide occupational accident rate by 25 percent compared with the 2010 baseline.