KERAMA MARAZZI: sustainability and environmental management
Sustainable business is the one that cares not only about its financials. True responsibility of the manufacturer starts with thinking about oneself as something more than just a “subject of economic relations.” The ability to see a global picture, care for the environment are the qualities which have been increasingly sought-after in today’s corporate culture.
Since our very first steps until present, KERAMA MARAZZI has evolved as a company pursuing conscious and responsible environmental policy. We take natural resources, process them and create new products, striving to mitigate our environmental impact across all phases. The company and every staff member of our numerous team are interested in ensuring our environmental impact to be positive and tomorrow’s world to become better than yesterday’s, together with KERAMA MARAZZI
The manufacturing niche of KERAMA MARAZZI has been traditionally considered to be one of the eco-friendliest. Natural raw materials serve as a basis for ceramic materials – like centuries ago, tiles almost 100% consist of natural clay. It is processed using state-of-the-art equipment in lean cycle, which fully involves all feedstock entering the line. At the same time, heated water vapor, which has previously undergone strict filtration, leaves the factory pipes into the atmosphere.
Meanwhile, the company annually directs tens of millions of rubles toward preserving natural resources and implementing solutions aimed at making its manufacturing processes even safer for the environment.
Our environmental programs include:
1. ongoing environmental monitoring at the manufacturing facilities in Oryol and Malino,
2. upgrade of the existing environmental protection equipment,
3. implementation of the projects aimed at reducing the consumption of natural resources,
4. full recycling of ceramic waste at manufacturing lines,
5. program for the disposal of waste generated in the course of manufacturing.
We undertake ongoing environmental monitoring
In order to monitor our environmental impact, the manufacturing facilities conduct the environmental monitoring of manufacturing process. It entails checking the composition of water vapor that leaves into the atmosphere and recording the quantity of consumed resources, such as water, natural gas, power. It also includes analyzing the qualitative and quantitative composition of the storm wastewater returning to water bodies, its conformity to industrial standards.
The objectives of environmental monitoring include recording the quantity of waste generated in the course of manufacturing. These are consumables for machines and process lines, including used machine oil, as well as a variety of packaging types in which the necessary components of the future tiles (dyes, glazing and decoration materials) enter into production
We upgrade environmental protection equipment
2019–2020 saw the implementation of several programs which contribute to mitigating the environmental footprint of KERAMA MARAZZI manufacturing facilities:
1. Upgrade of stormwater treatment plants at the Malino factory,
2. Installation of stormwater post-treatment system at the Oryol manufacturing facility,
3. Installation of additional filters at kilns (Malino).
(environmental projects in figures)
RUB 99M were allocated for environmental projects in 2020
8 environmental projects were implemented at the manufacturing facilities in Oryol and Malino
431 tonnes of paper and cardboard were sent to recycling facilities
266 000 m3 of water were saved due to eco-friendly technologies
1.7M m3 of gas were saved using heat from kilns
We reduce natural resource consumption
Water, natural gas, and power are absolutely necessary to make tiles and other ceramics. We at the manufacturing facilities of KERAMA MARAZZI follow lean manufacturing principles, i.e., seek to reduce the amount of resources we use and to maximize their efficiency.
Water resource saving is ensured by the employment of recycling water supply system. The factories of KERAMA MARAZZI collect and purify the water necessary for manufacturing processes, thus using it in a continuous cycle. The environmental projects implemented in 2020 include the expansion of treatment facilities at the Malino factory, which ensured a more efficient treatment of process water before its reuse.
The amount of water consumed to manufacture 1 kg of products went down by 3.5% in 2020 vs. last year to less than 0.92 L.
Another recently completed project is a system which allows the use of heat released in the firing of ceramic tiles in the manufacturing cycle. The operating temperature of the kiln is about 1,200 degrees. Part of this heat previously used to simply “go up in smoke” and now it enables perceivable energy saving. The project was implemented at the Malino factory. A similar technology was launched in Oryol, where hot air from kilns is, among other things, used in the space heating system, which allows saving approximately 2% of total gas consumption, some 2 million cubic meters per year.
The use of heat from kilns enabled saving 1,701,440 m3 of natural gas in 2020.
We recycle ceramic materials
Each phase of the manufacturing cycle generates materials which have failed technical control or have been categorized as waste for any other reasons. All of them may be reused – broken tiles are collected, crushed, and become feedstock for the manufacturing process again. That said, the standards governing the ability to employ such materials are fully adhered to.
The output of porcelain gres with reused content represented almost 17% in 2020. Raw material savings stood at 34,434 tonnes.*
*Data relates to the Malino manufacturing facility.
In an effort to reduce the quantity of industrial waste, we literally collect dust from our process equipment, primarily from press machines. This kind of “useful dust” is subsequently reused in moulding compounds.
We dispose of manufacturing waste
The principal waste accompanying the manufacturing process at the manufacturing facilities of KERAMA MARAZZI is diverse packaging of the components for future tiles we receive. The manufacturing sites offer a system of separate collection of plastic packaging, cardboard, paper and artificial fiber bags. Then waste is forwarded to a certified contractor for recycling.
In 2020, the quantity of plastic waste sent to recycling facilities stood at 123 tonnes; that of paper and cardboard waste, 431 tonnes.
Waste also includes used machine oil. We forward such materials to a specialized company in the business of lean disposal of this kind of waste.
We evelop environmental consciousness among industry players
Being the largest manufacturer of ceramic materials, KERAMA MARAZZI takes an active part in all meaningful sectoral initiatives, specifically related to the eco-friendliness of the materials we produce. These initiatives include the adoption of a new ceramic tile standard, which came into force on June 1, 2020. GOST 13996-2019 meetsical requirements for ceramic finishing at the federal level – no other finishing ma current realities and governs technterial boasts this.
KERAMA MARAZZI was directly involved in discussing the new GOST within the working group. This work was performed together with the Association of Manufacturers of Ceramic Material (AMCM). This organization helps advocate interests of eco-friendly and safe finishing in the market offering “substitute” products of varying quality, including those posing direct threat to human health.
The company is also a member of Green Building Council Russia. It boosts the development of all aspects of construction, ranging from eco-friendly design to the implementation of energy-efficient technologies.
We lead green certification
Environmental certification is an important condition for the participation of materials from KERAMA MARAZZI in sustainable construction projects. The availability of certificates also boosts interest from architects, designers, design engineers, and builders in cooperation with the company and the employment of our products.
It is noteworthy that most environmental certification procedures are voluntary in nature and promote higher business openness in line with the ethical standards of European companies.
1. Environmental Product Declaration of KERAMA MARAZZI
In 2020, KERAMA MARAZZI performed a Life Cycle Assessment (LCA) of its porcelain gres floor tile manufactured using BIa technology in Oryol and Malino, as well as its wall tile produced in Oryol in conformity with the EN 14411 standard. The company successfully passed the audit, based on findings from which it obtained the Environmental Product Declaration (EPD).
The Environmental Product Declaration of KERAMA MARAZZI is a detailed report on the environmental characteristics of products with due regard for their life cycle from clay pit to disposal. EPD confirms the environmental responsibility of a company and is currently considered to be one of the crucial documents in green construction. For example, a company is required to produce LCA and EPD certificates to be eligible to participate in state-run tenders in Northern European countries. In all other cases, environmental product declaration gives a tangible advantage in purchasing materials for buildings certified as conforming to LEED, BREEAM and other environmental standards.
Apart from other aspects, Environmental Product Declaration covers the improvement of corporate environmental indicators, such as
· reduction of emissions,
· reduction of raw materials consumption,
· energy saving,
· mitigation of adverse environmental impacts.
The environmental effects of a product throughout its life cycle are assessed in conformity with the international standards ISO 14040-44, EN 15804, EN 15978.
KERAMA MARAZZI is the first and so far the only company in Russia’s ceramic market to have this kind of declaration.
The information contained in the declaration is officially verified and confirmed by the Italian institute CERTIQUALITY. This company has extensive experience in performing an independent assessment of environmental product declarations and strong expertise in the ceramic industry.
The EPD and Climate Declaration of KERAMA MARAZZI are officially registered and published on the website of EPD at www.environdec.com.
2. LEED environmental certification
In 2014, the series of porcelain gres by KERAMA MARAZZI that are by 10%+ manufactured from recycled materials first [КЛ1] passed voluntary environmental certification. The certificate issued by independent international organization CERTIQUALITY confirms that our products fully meet the requirements of LEED (The Leadership in Energy & Environmental Design). This is a globally recognized voluntary certification system for the so-called “green buildings” which are designed and built in conformity with special environmental standards.
3. KEYMARK Certificate
In 2013, the independent Italian institute CERTIQUALITY issued UNI-EN 14411 certificate and KEYMARK 023 conformity mark in respect of КERAMA MARAZZI products. Certification entailed the assessment of control of compliance with manufacturing technologies, including the elements of the ISO 9001 quality management system, at manufacturing facilities in Oryol and Malino.
The certificate confirms the high quality of the products by КERAMA МARAZZI, their full conformity to the uniform European standards and technical specifications, as well as safety for consumers and the environment. The KEYMARK is awarded based on findings from tests for conformity to the requirements of the European standards, as well as from audit at the manufacturing site. Since KEYMARK is a European mark, all tests are conducted in conformity with the applicable standards of the European Committee for Standardization.