Bentley Motors Environmental Strategy
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Bentley Motors Environmental Strategy 21/08/14 Andrew Robertson
Bentley Motors Environmental Strategy
Worked in the Automotive Industry for 25 years
Responsible for the Site Planning Department at Bentley Motors in Crewe for
the last five years.
During this time -
Bentley became the first automotive company to achieve ISO 50001
Bentley installed, what was at the time of installation, the largest roof
mounted solar PV system in the UK
Eur Ing Andrew Robertson BEng
Gained the hat trick of the Carbon Trust Standards
(Hons) CEng MIET CEnv FSOE
Head of Site Planning
Bentley Motors Limited As Chartered Engineer and Chartered Environmentalist, responsible for both
the operational performance of the Site and it’s environmental impact and
certification.
2
Bentley Motors Environmental Strategy
The Bentley Site in Crewe
• The Bentley Motors factory is located in Crewe, Cheshire
• It is a fully integrated site – all aspects of car production from Design, Engineering, Manufacture, Quality, and Sales &
Marketing take place in Crewe
• The Site covers an area of 434,891m2, with 151,522 m2 under cover
3
Bentley Motors Environmental Strategy
What we have achieved in the last 13 years…
Absolute Reductions of ….
Total Energy Usage (2000 — 2013) Down 14%
CO2 From Energy Usage (2000 — 2013) Down 7%
Total Water Usage (2000 — 2013) Down 50%
Waste per Car (2000 — 2013) Down 84%
Environmental Incidents (2005 — 2013) Down 100%
Recycling (2005 — 2013) Up 33%
First Automotive Company to get ISO 14001
First Automotive Company to get ISO 50001
First Automotive Company to get Carbon Trust hat trick; Energy, Water and Waste
Against a background of increasing production tenfold in the same period
4
Bentley Motors Environmental Strategy
How did we do all this ?
We………..
• Started a long time ago
• Defined what we wanted to achieve
• Set out a long term strategy
• Measured where we were
• Conducted a gap analysis
• Addressed high energy use on Site
• Engaged senior management in the Environmental agenda
• Constantly reviewed new technologies
• Treated the activity as a marathon not a sprint
• Reported performance
5
Timeline
ISO EN ISO Carbon UK’s largest Carbon Carbon
14001 16001 50001 Trust Solar PV Trust Trust
Energy System Water Waste
Standard goes on line Standard Standard
Green Water Main Removal of Centralisatio Zero to
Travel Replacemen Desk Bins n of Waste Landfill
Policy t Yard
6
Total Energy Usage
Throughout the last decade energy has been managed to achieve a reducing
trend.
TOTAL ENERGY
In absolute terms energy usage has reduced from 136 GWhs in 2000 down to
118 GWhs in 2013.
•
•
USAGE
Measure your usage
Target large consuming processes or buildings
30,000
Energy per Vehicle Produced
25,000
• We looked to stop using energy in the first place rather than recovering it 20,000
•
kW h's
Specify all new equipment to be efficient 15,000
•
10,000
Inverter controls on motors 5,000
• Not oversizing motors and equipment 0
2009 2010 2011 2012 2013
• Stop leaks and waste Energy per Car 25,225 22,896 13,974 11,897 10,957
• Avoid compressed air and steam Total Energy - Cars Produced
150 12,000
10,000
We are now setting energy targets by area 100 8,000
GWh's
Cars
6,000
50 4,000
2,000
0 0
2000
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011
2012
2013
Total Energy GWh's Cars produced
7
Solar PV
• Generate your own if you can
Site Electricity Supply 2013/14
• In April 2013 Bentley’s 5.1 MW Roof Mounted Solar
PV array was commissioned , providing circa 15% of 4,000,000
Bentleys electrical requirement.
3,500,000
• To date the system has generated a total of 3,000,000
5,153,253 kWhs with 286,200 kWhs being exported 2,500,000
kWh's
to the Grid
2,000,000
SOLAR
• It was sized to cover base load 100% 1,500,000
1,000,000 GRID
500,000
0
8
Water
• Throughout the last decade we have improved water 250,000 12,000
usage efficiency - we have achieved this by ..
• Overhauled the infrastructure
• Eliminated high water usage processes on Site. 10,000
200,000
• Installed circulating systems
• In 2000 we used 198,276 cubic meters of water - this 8,000
has been reduced by 50% down to 99,592 cubic 150,000
W at er m 3
meters in 2013.
Car s
6,000
• Replacement and modernisation of major sections of 100,000
both the water main and fire hydrant systems across
4,000
Site, have eliminated many underground leaks.
• Modernisation of the on-Site Domestic systems was 50,000
2,000
completed
• Smart flush systems
• PIR sensor taps 0 0
2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013
Water Consumption Cars
9
Waste
• Waste per car performance which peaked as high as 2.74 tonnes per car is now down to 0.42 tonnes per
car - this represents an 84% improvement.
• We achieved zero waste to landfill in April 2013.
• The current recycling rate in excess of 97%
• We centralise waste collection on Site in our own recycling centre
– We recycle Office Paper, Cardboard, Plastic, Cans, Printer Cartridges, & Batteries.
– Waste from Production is segregated with Paper, Cardboard, Plastic, Wood, Metals, Trade Effluent &
Batteries being recycled.
– Construction Waste is sorted off Site and 100% recycled.
– We do not allow scrap to be taken away by others
10CO2
• The total CO2 produced by the Site of 33,963 tonnes in 2000 has been reduced by 1,473 tonnes per
annum representing a 7% reduction.
• CO2 per vehicle manufactured has reduce by 56%, down from 6.66 tonnes in 2009 to 2.92 tonnes in
2013.
7.00
Cars Produced - CO 2 from Energy Use Tonnes CO 2 / Car
6.00
40,000 12,000
5.00
10,000
30,000 4.00
tonnes CO 2
8,000
tonnes CO 2
Cars
20,000 6,000 3.00
4,000 2.00
10,000
2,000
1.00
0 0
2000 2002 2004 2006 2008 2010 2012 0.00
2009 2010 2011 2012 2013
Total CO2 Cars Produced Tonnes of CO2 per
6.66 5.86 3.78 3.20 2.92
Vehicle
11Environmental Incidents
• Since 2005 Environmental Incidents have shown an improving trend, and have reduced by 100% since
establishing the database in 2005.
• During 2013 we had zero incidents recorded
• In 2014 the Environment Agency moved us to self monitoring
12Other things to consider
• BREEAM Certification for new buildings
• We adopted this not for the certification but for the discipline it drove in the process of design
• Lighting
• Factory built using “North Light” construction, maximising natural light & minimising thermal input.
• Use of “T-5” Fluorescent lamps gave 20% saving in energy.
• Motion sensors installed in all new buildings and refurbishments since 2010.
• Move to LEDs
• Identify your drainage
• Independent Surface Water & Foul Water Drainage Systems clearly identified.
• Stop things going down them that shouldn’t
• Have a spilt kit process
• Look for smart solutions
• Aerosol Crusher
• Refrigerants with a low Ozone Destruction and Global Warming potential used.
• Biodrier Hand Driers minimises energy consumption by using the heat from its own motor to provide hot air for hand drying,
• Use sensors to ensure things activate only when they are needed
• Use of rechargeable Battery Powered Tools.
• Energy recovery from Engine Test Cell Dynamometer.
• Process to adhere to the European Minimum Energy Performance Standard (MEPs) for all new and replacement Electric Motors.
13ISO50001 Energy Management System
• Energy Management in Context
• Why Energy Management? Energy Carbon Environmental
Management
• Rising fuel costs Management Management
• Rising energy costs
• Climate Change Levy
• Energy Security
• Depletion of fossil fuels
• Political instability of primary energy supplying countries
• Legislation
• EU Emissions Trading Scheme
• Carbon Reduction Commitment
• The right thing to do !
14Summary
• Define what you want to achieve
• Set out a long term strategy
• Measure where you are and conduct a gap analysis
• Identify applicable legal and other requirements
• Address high energy use on Site
• Engage senior management in the Environmental agenda
• Constantly review new technologies
• Treat the activity as a marathon not a sprint
• Report Performance
• Address relevant resources, roles and responsibilities to meet all the above
• Carry out appropriate awareness campaigns and training to ensure
competence and adequate communication
• Regularly review and update activities
• Celebrate Success
1516
Where Next
• We continue to plan for the future
• Further investment in the Factory driven by the new SUV programme
• Exciting plans for more renewables
• Continue to focus on reducing waste
• Add the reduction of VOCs to our Environmental Strategy
17Any Questions?
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