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Fresenius Kabi

An integral component of the quality management of Fresenius Kabi is an environmental management system that complies with the international standard ISO 14001. We are also pursuing the implementation of the occupational health and safety assessment system OHSAS 18001.

Our goals are:

  • to decrease the waste volume at our production sites and sales offices, and
  • to efficiently and carefully use energy to reduce emissions.

These goals lead to individual objectives for our locations.

In 2011, Fresenius Kabi continued the matrix certification for the environmental management system. As part of the certification, we analyze and assess work flows and processes according to sustainability criteria, and document the responsible use of energies and natural resources as well as employee safety and protection of the environment. This allows us to reveal opportunities for improvement, both with regard to the value chain and how we deal with external partners. Our international production network improves, for example, delivery to our customers and reduces emissions associated with transportation. Our goal is to base all internal and external processes not only on economic, but also ecologic provisions, and to expand the matrix certification to other production sites and sales offices.

At our production sites in Friedberg and Bad Homburg, Germany, the recycling rate in 2011 of more than 97% was slightly above the previous year’s figure of about 97%. Approximately 5,800 t of waste were recycled (2010: approximately 5,600 t). The waste volume rose by 3% in Friedberg and by 21% in Bad Homburg. This was mainly attributable to the increase in production volume for enteral nutrition products. This also led to a higher energy consumption. The percentage of renewable energies of the total energy consumption is approximately 23%.

In 2011, Fresenius Kabi continued to implement measures to reduce energy consumption, CO2 emissions and the consumption of raw materials. Fresenius Kabi uses, for example, the produced coolant heat to heat the logistics spaces. In addition, we use dark radiators in production areas. These radiators use energy-efficient infrared technology. It ensures the heating of work spaces only close to the floor, and saves approximately 30% of the energy used by traditional heating systems. The difference is that the air close to the ceiling is not unnecessarily heated.

In 2011, Fresenius Kabi invested in the modernization of its technical systems, for example the pressure decrease in the compressed air system. This reduced the system’s CO2 emissions. In addition, waste water is used to compensate for condensation losses in the steam generator system in order to reduce water consumption. A landscaped roof now protects the building better against heat in the summer, and reduces the heat loss in winter. It also significantly slows down the roof’s aging process.

All these activities not only serve the primary purpose of environmental protection, but also helped to reduce energy costs in 2011.

In Austria, the production sites in Graz and Linz have an integrated management system for quality, the environment, safety, and risk. Long-term goals are to guarantee and continuously improve the efficiency of the environmental management, to handle environmental resources carefully, and to keep the impact on the environment as small as possible.

The environmental management system at the site in Graz has been certified pursuant to ISO 14001:2004. The system defines various environmental performance indicators, such as the recycling rate. In 2011, we further optimized our waste processing and energy consumption. The recycling rate increased significantly from about 70% in 2010 to now 85%. We are working closely with the local waste management companies, thus consequently improving our waste collection and separation system. 14% of the waste volume serves as energy source, and is used in thermal waste treatment plants. The remaining 1% is taken to a biogas plant or chemically processed. In addition, the logistics department optimized the transport packaging. This allows us to sustainably save about 2 t of plastic waste each year.

At the Graz location, we review the energy consumption every year in order to identify new savings opportunities. Since 2010, we have been successively switching to LED bulbs. We continued this project in 2011 and decreased energy consumption by 10,000 kWh.

Since 2010, the environmental management system of the production site in Linz is also certified pursuant to ISO 14001:2004.

In 2011, energy consumption of 46 GWh was at the previous year’s level despite a significantly higher production volume. Already in 2010, we had started to successively switch our production processes to energy-efficient technologies. We decreased our energy consumption in the years 2010 and 2011 by a total of 55,000 kWh. All old systems in the agitators will be replaced by 2013. We also decommissioned the oil heating system at the site. We are now covering our energy needs with natural gas. It is therefore no longer necessary to pre-heat the oil and maintain a certain temperature in the storage tanks. This leads to an additional savings of 85,000 kWh per year.

In 2011, we also improved our waste processing and reduced commercial waste similar to household waste by 10%.

Other long-term measures are planned that will save energy and other resources in the future in the interest of successful environmental management.

At our Swedish production plants in Uppsala and Brunna, the waste volume increased in 2011 to 4,751 t (2010: 4,073 t). Thanks to the projects initiated earlier in the disposal area, the waste increase is much lower than the increase in production volume.

Energy consumption decreased compared to the previous year by 9% or 10 GWh, also because of the energy savings initiatives that were started the year before. Approximately 43% of the energy needed at both sites is covered by renewable energies. At the Brunna plant, we have decreased energy consumption by using a band filter, in order to reduce solvent extraction, and by starting to operate an energy-efficient cooling tower.

Water consumption amounted to about 232,266 m3, which is slightly above at the previous year’s level. In Uppsala, we switched from a fresh water cooling system to a centrally controlled cooling system that is supplied by a long-distance cooling network. Heat energy, for example, from waste incineration plants, is used to cool down water. Fresenius Kabi obtains this long-distance cooling through insulated pipelines directly from the producer. This reduces the demand for water, and additionally, the system is more energy-efficient.

We were also able to lower our use of nitrogen: The performance parameters that were implemented in 2010 in production have improved the monitoring of wire lines and thus reduced consumption.

Fresenius Kabi also integrates standardized requirements for health, safety, and environmental protection into its quality management system. In the manufacturing of pharmaceuticals, the employees of Fresenius Kabi sometimes have to work with toxic substances. Consequently, protecting the environment, and the health and safety of our employees is of utmost importance. New requirements relating to occupational health and safety are integrated into our quality management, e. g. those in the REACH Regulation (Registration, Evaluation, Authorization and Restriction of CHemicals).

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