DIC's Responsible Care System
Responsible Care Care Report Report Responsible
2002
Dainippon Ink and Chemicals, Incorporated Corporate Headquarters : DIC Building, 7-20, Nihonbashi 3-chome, Chuo-ku, Tokyo, Japan 103-8233 Date of Foundation : February 15, 1908 Date of Incorporation : March 15, 1937 Paid-in Capital : ¥82,423 million (As of March 31, 2002) Number of Employees : 5,082 (As of March 31, 2002) Net Sales : ¥370,381 million (Fiscal 2001)
CONTENTS A Message from the President
1
Principle and Policy for the Environment, Safety and Health
2
ESH Activities
5
1. Environmental Costs and Safety- and Health-Related Expenses and Investments 2. Safety and Health Record 3. Environmental Load Reduction 4. Safety Control of Chemical Substances 5. Safety during Transportation 6. Green Procurement 7. Soil Analysis at Former Plant Sites
Development of Environment-Friendly Products
12
ESH in Research and Development and New Businesses
14
ESH in International Operations
14
ESH in International Transactions
14
Interaction with the Local Community
15
DIC Plants / R&D Center
15
Introducing the Mikawa Plant
16
History of DIC’s Environment and Safety Program
17
Environment and Safety Awards Received by DIC
17
Responsible Care Care Responsible DAINIPPON INK AND CHEMICALS, INCORPORATED
A Message from the President Dainippon Ink and Chemicals, Incorporated (DIC), dedicates itself to being a creative and distinctive organization capable of innovating products that enhance the lives of people around the world. In line with this philosophy, we have cultivated operations in our core businesses, notably graphic arts materials and polymers and related products, and currently have subsidiaries and affiliates in 64 countries around the world. We recognize that care for the environment, safety and health (ESH) is fundamental to management and seek to incorporate these concerns in all aspects of our activities. In 1992, we formulated and publicly announced an official principle and policy recognizing the importance of care for the environment, safety and health. The principle and policy were reaffirmed in 1995, when we unveiled and began implementing our Responsible Care program as one of the 74 founding companies of the Japan Responsible Care Council. Since then, we have made substantial progress on several fronts, including reducing environmental load, lowering consumption of energy and resources, minimizing the generation of industrial waste, improving control of chemical substances and eliminating accidents at our plants. Fiscal 2001, ended March 31, 2002, brought a number of notable achievements. For example, efforts to revamp production processes contributed to a reduction in energy consumption of 2.6% per unit (ton) of production from fiscal 2000, and 16% from fiscal 1990. Efforts to reduce environmental load led to a decrease in carbon dioxide emissions of 2.5% from the previous fiscal year, or 22% from fiscal 1990. We also slashed the volume of waste disposed of as landfill 30%, or 57% from 1990. In the area of product development, we introduced Naturalith 100, a series of 100% vegetable oil-based offset inks containing no volatile organic compounds (VOCs) and low-VOC decorative boards that improve room air quality. Naturalith 100 was honored with the Japan Chemical Industry Association (JCIA) Technology Prize for 2002. The DIC Group will continue to address key tasks to promote sustained growth and development, harmony with the environment and awareness of recycling, as well as to earn the trust of people worldwide. I am pleased and proud to present DIC’s Responsible Care Report 2002, which summarizes the results of our ESH activities during fiscal 2001. We welcome and appreciate comments or advice from readers regarding our activities and the content of this report. September 2002
President and CEO
1
Responsible Care Care Responsible DAINIPPON INK AND CHEMICALS, INCORPORATED Principle and Policy for the Environment, Safety and Health [Principle]
As a responsible corporate citizen, Dainippon Ink and Chemicals, Incorporated (DIC), recognizes that care for the environment, safety and health (ESH) is fundamental to the management of the Company. DIC is committed to the concept of sustainable development and contributes to society by creating environmentally sound products and technology. [Policy] 1.
We establish ESH-related objectives and targets and pursue continual progress.
2.
We comply with laws, regulations and agreements relevant to ESH.
3.
We consider the ESH implications of each of our products throughout their life cycles in accordance with the ideals of Responsible Care.
4.
We instill in our employees a thorough understanding of this fundamental Principle and Policy.
5.
We organize our operations so as to promote the safeguarding of the environment, safety and health and conduct audits to monitor progress throughout the Company.
6.
We ensure that operations are conducted safely and materials are handled properly. We try to prevent environmental pollution and avoid affecting the environment negatively by recycling waste, conserving energy and other resources and using materials that are environmentally friendly.
7.
We place the utmost importance on ESH-related considerations at all stages of the new product planning and production process.
8.
We promote safety by providing customers with detailed instructions on the proper use and handling of all products.
9.
In our overseas activities, we conduct environmental impact assessments and strictly observe local ESH regulations. In the absence of such regulations, we work with local officials and our business partners to develop environmental safeguards. We also follow this procedure when dealing with toxic materials, applying the same stringent standards for their handling as required in Japan. In addition, we promote the transfer of technology and know-how related to environmental protection.
10.
We provide the public and appropriate authorities with ample information about our products and business activities so that they may have an accurate understanding of our efforts to promote health, safety and environmental protection. The above Principle and Policy shall be available to all employees and to the general public. It is our goal that this Principle and Policy be followed at all DIC Group companies.
Established April 1, 1992 Revised February 1, 1996
2
2002 DIC’s Responsible Care System 1. Responsible Care Organization (Environment, Safety and Quality Management) DIC has appointed an executive charged with setting up an Environment, Safety and Quality Management Department and with overseeing Responsible Care activities.
XXXX Branch Office
XXXX Division
XXXX Office
Responsible Care Department
President
Safety and Quality Management Supervisor
XXXX Office Safety and Quality Management Supervisor XXXX Branch Office Safety and Quality Management Supervisor
Director in charge of Responsible Care XXXX Division
Safety and Quality Management Supervisor
DIC Central Research Laboratories Environment, Safety and Quality Management Department XXXX Plant
Domestic subsidiaries and affiliates Overseas subsidiaries and affiliates
Environment, Safety and Quality Management Department XXXX Plant Environment, Safety and Quality Management Section
Fig. 1 DIC’s Environment, Safety and Quality Management Organization
2. Responsible Care Organization DIC’s Responsible Care organization comprises two bodies, which are responsible for decision making and monitoring activities, respectively.
１）Decision-Making System
Environment and Safety Conference As the principal decision-making body for Responsible Care activities, DIC has established the Environment and Safety Conference at its head office. This conference includes the executive vice president, relevant directors, executives in charge of Responsible Care at each DIC plant and general managers of relevant business divisions at the head office.
3
Responsible Care Care Responsible DAINIPPON INK AND CHEMICALS, INCORPORATED DIC’s Responsible Care System
Divisional System At each DIC plant and research facility, an Environment and Safety Committee has been established and environment, safety and quality control personnel assigned. DIC has also assigned a Safety and Quality Management Supervisor to each sales office. All of DIC’s principal plants have obtained ISO 14001 certification, the International Organization for Standardization’s global benchmark for environmental management systems, allowing them to measure Responsible Care efforts against internationally accepted criteria. Plants and the fiscal year in which each obtained ISO 14001 certification are: Fiscal 1996 Fiscal 1997 Fiscal 1998
Kashima Plant Sakai Plant; Amagasaki Plant; Mikawa Plant; Chiba Plant; Tokyo Plant, Saitama Plant; Yokkaichi Plant; Gunma Plant; Komaki Plant Suita Plant; Warabi Plant; Nagoya Plant
２）Internal Audit System DIC’s internal Responsible Care audit system is overseen by the Responsible Care Review Committee and includes periodic audits by top executives from the head office as well as internal audits.
Responsible Care Review Committee The Responsible Care Review Committee comprises directors and general managers of relevant business divisions of the parent company and monitors the Responsible Care activities of each plant on an annual basis.
Audits by Top Executives Inspection teams consisting of the general manager and staff of the parent company’s Responsible Care Department and led by top executives monitor the Responsible Care activities of each plant through on-site audits.
Internal Audits Individual plants, laboratories and offices conduct periodic internal audits. Board of Managing Directors/Board of Directors
Responsible Care Review Committee Audits by top executives
President
Environment and Safety Conference
Environment, Safety and Quality General Managers’ and Managers’ Committee Safety and Quality Management Supervisors' Committee Plant Environment and Safety Committees (RC Committees) DIC Central Research Laboratories’ Environment and Safety Committee (RC Committees)
4
Fig. 2 DIC’s Responsible Care Organization
Internal audits Internal branch and sales office audits Audits of domestic and overseas subsidiaries and affiliates
2002 ESH Activities 1. Environmental Costs and Safety- and Health-Related Expenses and Investments 1 ）Environmental Costs In line with the Preparation for Establishment of an Environmental Accounting System (2000 Report), published by Japan’s Environment Agency, we have calculated amounts for environment-related expenses and investments in fiscal 2001. Environment-related expenses totaled ¥8,958 million, while investments amounted to ¥1,191 million. Of total environment-related expenses, 40% was accounted for by measures to prevent pollution and protect the environment, 53% by environmental R&D, 4% by environmental control measures and the remaining 3% by other measures. Other measures 3％ Environmental control measures 4 ％
Measures to prevent pollution and protect the environment 40％
Environmental R&D 53％
Fig. 3 Breakdown of Fiscal 2001 Environmental Expenses Millions of yen
Environmental Costs Category
Scope
1. Costs incurred through activities aimed at minimizing environmental load generated within the business area through production and sales activities (costs within the business area)
Investments
Expenses
Costs related to the preservation of air and water quality, maintenance or improvement of waste disposal and recycling activities
￥517
￥3,546
Costs related to the preservation of air and water quality
350
1,811
･ Operating/maintenance expenses related to activities aimed at curbing air pollution (310), global warming (180), water pollution (1,010), soil pollution prevention expenses (3) and other expenses ･ Investments in air pollution prevention activities (227), water pollution prevention activities (120) and other investments
(a) Pollution prevention and environmental protection costs
Costs related to the maintenance or improvement of energy consumption and internal and external waste disposal
167
1,736
･ Operating/maintenance expenses for activities aimed at reducing energy and resource consumption (530), water consumption (2) and waste disposal (1,090), expenses related to the obligatory recycling of used merchandise (0.2) and other expenses
(b) Resource recycling costs
･ Investments in activities aimed at reducing energy consumption (120), waste disposal activities (50) and other investments
2. Environmental costs related to management activities (management activity costs)
3. Environmental costs related to technological activities (technological activity costs) (Note 2)
Costs related to environmental and safety promotion and education; environmental management and auditing related to acquisition of ISO14001 certification ･ Personnel/administrative expenses (250), ISO 14001 maintenance expenses (12), environmental load measurement expenses (64) and other expenses Expenses and investments related to the development of products that reduce environmental burden (including personnel expenses)
( Note 1)
368
665
4,796
9
175
0
73
￥1,191
￥8,958
Costs of plant and office greening programs and shared costs
4. Environmental costs related to social activities (social activity costs)
･ Internal maintenance expenses (55), fees to external organizations (78) and other expenses ･ Investments in greening programs (8)
5. Costs related to damage inflicted on the environment (environmental damage costs)
Environmental clean-up and other expenses ･ Levies on lake development (65) and other expenses
Total
Notes: 1. The investment portion of management activity costs is included in costs within the business area. 2. Technological activity costs are costs related to the development of products that reduce environmental burden and include R&D costs for new products as well as the improvement/customization of existing products.
5
Responsible Care Care Responsible DAINIPPON INK AND CHEMICALS, INCORPORATED
millions of yen Category
Composition
Expenses
Investments in facilities to reduce environmental burden and lower energy and resource consumption; other investments
Environment-related facility investments Percentage of total facility investments
￥1,191
6.2% Investments related to environmental conservation technologies and the development of products that reduce environmental burden
Environment-related technology costs Percentage of total technology costs
5,461
19.0%
See pages 8–11 for detailed data on the impact of DIC’s environmental conservation measures since fiscal 1990. millions of yen Economic Effects of Environmental Conservatioin Measures Category
Expenses
￥390
Income earned by waste recycling
270
Treatment cost reduction through waste recycling Cost reduction through energy conservation
229 ￥889
Total
Table 2
Impact of Measures to Protect the Environment Impact of Measures to Protect the Environment Environmental Load Index
1. Impact of environmental protection measures within the business area
· CO2 emissions (calculated in tons of carbon) per unit of production
78.8% (fiscal 1990=100)
· SOx emissions per unit of production
25.5% (fiscal 1990=100)
· NOx emissions per unit of production
70.7% (fiscal 1990=100)
· COD emissions per unit of production
60.0% (fiscal 1990=100)
· Energy used (calculated in volume of crude oil used) per unit of production
84.4% (fiscal 1990=100)
· Emissions of solid wastes disposed of through burial by external companies
43.1% (of the fiscal 1990 level)
· Fees paid for the disposal of solid wastes through burial by external companies (fiscal 2001 actual payment basis) were ¥830 million lower than in fiscal 1990. (Note 1) · Emissions of Pollutant Release and Transfer Register (PRTR) chemicals were 76.1% of the fiscal 1999 level. (Note 2)
2. Impact of environmental protection upstream and downstream measures
· The reduction in CO2 emissions realized as a result of modal shifts was 35.8% higher in fiscal 2001 than in fiscal 1999. (Note 3)
Notes: 1. The comparison of fees paid for the disposal of solid wastes through burial by external companies (fiscal 2001 actual payment basis) was calculated by subtracting the fiscal 2001 total from the fiscal 1990 total. 2. Figures represent emissions of PRTR chemicals based on a revised list of target chemicals that went into effect in fiscal 2001 and is retroactive to fiscal 1999. (The new list encompasses 480 chemicals, of which DIC uses 120.) 3. Calculations are based on standards set forth by the Japan Federation of Freight Industries in its Report on Survey of Modal Shifts. The aim is to compare how much greater a reduction in CO2 emissions was realized through the use of large-scale transport modes in fiscal 2001 than in fiscal 2000.
２）Safety- and Health-Related Expenses and Investments Safety- and health-related expenses in fiscal 2001 totaled ¥72.0 billion, while safety- and health-related investments were ¥36.1 billion. Pertinent safety and health management activities accounted for 56% of expenses, while fees paid to outside firms for safety data-related tests represented 7%, safety and fire prevention measures totaled 19% and specific safety and health-related measures amounted to 18%. Safety and fire prevention measures 1 9 %
Safety and health management activities 56%
Fees paid to outside firms for safety data-related tests 7 %
Specific safety- and health-related measures 18%
6
Fig. 4 Breakdown of Safety- and Health-Related Expenses
2002 ESH Activities
2. Safety and Health Record
DIC was honored to receive several awards during fiscal 2001 in recognition of its superb safety record and accumulated experience in ensuring employee safety. DIC: Chairman’s Award (Japan Industrial Safety and Health Association) Saitama Plant: Top Hazardous Substance Operation Commendation (Commissioner, Fire Defense Agency) First Prize (Safety) (Minister of Health, Labour and Welfare)
During fiscal 2001, two accidents resulting in an absence of more than one day were reported at DIC plants, one more than in the previous fiscal year. The labor accident frequency rate for the period was 0.52 and the labor accident severity rate was 0.093, compared with 0.12 and 0.010, respectively, in fiscal 2000. Figures 5 and 6 show DIC’s labor accident frequency and severity rates from fiscal 1990 through fiscal 2001. Labor accidents are defined by DIC and the Japan Chemical Industry Association(JCIA) as accidents resulting in a suspension of operations for more than one day and by the chemical industry as accidents resulting in a suspension of operations for more than four days.
DIC
JCIA
Chemical industry
Frequency
1.5 1.0 0.5 0 1990
1991
1992
1993
1994
1995
1996
1997
1998
1999
2000
2001 Fiscal year
Fig. 5 Labor Accident Frequency Rate
DIC
JCIA
Chemical industry
0.25
Severity
0.20 0.15 0.10 0.05 0.00 1990
1991
1992
1993
1994
1995
1996
1997
1998
1999
2000
2001 Fiscal year
Fig. 6 Labor Accident Severity Rate
The first of the two accidents in fiscal 2001 that involved injuries resulting in a suspension of work happened when an employee backed into a piece of equipment on a production line, causing broken ribs. The second accident also involved broken ribs, in this case sustained when an employee was trapped between two pieces of equipment. Both injuries were treated and healed, resulting in no lasting impairment. Note: Labor accident frequency rate = Number of accidents and injuries due to labor accidents per one million hours of labor Example: A labor accident frequency rate of 1.0 corresponds to one accident per year in a workplace with 500 employees. Labor accident severity rate = Number of work hours lost per one thousand hours of labor Example: A labor accident severity rate of 0.1 corresponds to 100 work hours lost per year in a workplace with 500 employees. These terms were developed by the JCIA, which has 197 member companies. “Chemical industry,” as used in these figures, is a classification used by the Ministry of Health, Labour and Welfare for reporting labor accident statistics.
7
Responsible Care Care Responsible DAINIPPON INK AND CHEMICALS, INCORPORATED ESH Activities
3. Environmental Load Reduction 1 ） Emissions of CO2, SOx, NOx and COD
Emissions of CO2 have declined significantly thanks to several factors, including improvements in production processes and the introduction of cogeneration systems at principal plants between fiscal 1990 and fiscal 1998, and to ongoing efforts to reduce energy consumption. The following four figures index DIC’s emissions of carbon dioxide (CO2), sulfur oxide (SO x ), nitrogen oxide (NOx) and chemical oxygen demand (COD) per unit (ton) of production from fiscal 1990 through fiscal 2001 (fiscal 1990=100).
Emission Index
Thousands of tons
100 90
100
Goal
80
80 70 60
60
50 40
40
30 20
20
10
0
Emission Volume
Emission Volume
120
0
1990
1991
1992
1993
1994
1995
1996
1997
1998
1999
2000
2001
2010 Fiscal year
Fig. 7 CO2 Emission Index (fiscal 1990=100)
DIC’s SO x, NO x and COD indices remain favorable and stable and are well below legislated or stipulated levels.
Emission Index
120 100 80 60 40 20 0 1990
1991
1992
1993
1994
1995
1996
1997
1998
1999
2000
2001 Fiscal year
2000
2001 Fiscal year
Fig. 8 SOx Emission Index (fiscal 1990=100)
Emission Index
120 100 80 60 40 20 0 1990
1991
1992
1993
1994
1995
1996
1997
1998
1999
Fig. 9 NOx Emission Index (fiscal 1990=100)
8
2002 ESH Activities Emission Index
120 100 80 60 40 20 0 1990
1991
1992
1993
1994
1995
1996
1997
1998
1999
2000
2001
Fiscal year
Fig. 10 COD Emission Index (fiscal 1990=100)
２）Energy Consumption Energy consumption peaked in fiscal 1993, owing to the construction of a new plant early in 1990 and the start of operations at the plant in 1993. Between fiscal 1996 and fiscal 1998, DIC installed cogeneration systems at three plants. In fiscal 1999, the Company installed highly productive manufacturing facilities utilizing new energy technologies at the Yokkaichi Plant. As a consequence, energy consumption per unit (ton) of production at the plant decreased approximately 40% in fiscal 1999. The new facilities, together with ongoing efforts to reduce energy consumption, have also contributed to a steady decrease since fiscal 2000.
Consumption Index
Thousands of tons
160 140
100
Goal
80
120 100
60
80
40
60 40
20
20
0
0
1990
1991
1992
1993
1994
1995
1996
1997
1998
1999
2000
2001
Consumption Volume
Consumption Volume
120
2010 Fiscal year
Fig. 11 DIC’s Energy Consumption per Unit (ton) of Production from Fiscal 1990 through Fiscal 2001 (fiscal 1990=100).
３） Industrial Waste Figure 12 illustrates the annual volume of industrial waste generated by DIC that has been disposed of as landfill by external companies since fiscal 1990. In line with its commitment to helping promote a more recycling-oriented society, DIC has set forth an industrial waste disposal goal for fiscal 2010 of 5% below the fiscal 1999 level. To this end, in fiscal 2001 DIC established a special project team. As a consequence, the volume of industrial waste generated by DIC disposed of as landfill in fiscal 2001 declined approximately 30% from fiscal 2000.
Volume of Industrial Waste Disposed of as Landfill
Tons/year
16,000 14,000 12,000
Goal
10,000 8,000 6,000 4,000 2,000 0
1990
1991
1992
1993
1994
1995
1996
1997
1998
1999
2000
2001
2010
Fiscal year
Fig. 12 Volume of Industrial Waste Disposed of as Landfill by External Companies
9
Responsible Care Care Responsible DAINIPPON INK AND CHEMICALS, INCORPORATED ESH Activities
４） Polluting Chemical Substance Emissions ① PRTR Chemicals
DIC used 120 of the 480 PRTR chemicals in fiscal 2001. Total emissions of these chemicals during the period amounted to 652 tons, down 13.0% from 749 tons in fiscal 2000. This reduction is attributable to the installation of solvent recovery facilities and the integration of plants, which boosted operating rates for recovery facilities at remaining plants.
t/y 2,500
Emissions of Polluting Chemical Substances
In fiscal 2001, JCIA increased the number of PRTR chemicals—polluting chemical substances for which it requires its member companies to register and monitor emissions—to 480, from 284. As well, JCIA lowered the minimum annual emission volume for PRTR qualification from 10 tons to five tons for most PRTR chemicals and 0.5 tons for those that are carcinogenic.
Based on previous JCIA standards (284 chemicals) Based on current JCIA standards (480 chemicals)
2,000 1,500 1,000 500 0
1996
1997
1998
1999
2000
2001
Fiscal year
Fig. 13 Emissions of Polluting Chemical Substances
Table 3
Figure 13 shows DIC’s emissions of all PRTR chemicals since fiscal 1996. Table 3 shows fiscal 2001 emissions of those PRTR chemicals for which emission levels exceeded 10 tons. The Ministry of Economy, Trade and Industry has issued guidelines for the 12 PRTR chemicals it has designated “ priority ” chemicals, in line with which manufacturers conduct voluntary atmospheric contamination control programs. In fiscal 2001, DIC used six of these “priority” chemicals, the same number as in fiscal 2000, while its emissions of these six chemicals totaled 13 tons, down 13% from the previous term. Note: PRTR chemicals encompass polluting chemical substances for which JCIA requires companies to register and monitor emission levels and chemicals targeted by the Law Concerning Reporting, etc. of Release to the Environment of Specific Chemical Substances and Promoting Improvements in Their Management.
PRTR Chemicals with Emissions in Excess of 10 Tons in Fiscal 2001 Chemical
Volume Manufactured /Used
Volume Emitted
Ethyl acetate
13,725
106
Toluene
13,083
96
Xylene
8,957
81
Methyl ethyl ketone
9,765
78
Methyl ethyl alcohol
4,086
58
23,665
33
N–Methylpyrrolidone
162
23
HCFC–141b (under different names)
379
23
6,779
18
Methyl alcohol
N,N–dimethylformamide Styrene
161,273
13
Butyl alcohol
6,381
14
1,3–butadiene
1,844
12
192
12
1,003
11
Methyl cellosolve Propylene oxide
② Compliance with Dioxin Emission Control Regulations DIC currently has three incinerators at three plants that qualify as “specified facilities” under the Law Concerning Special Measures Against Dioxins. One of these incinerators, which has a maximum hourly capacity of 200 kilograms, is scheduled to cease operating by December 2002, when measures relating to such “specified facilities” will be introduced. The remaining two incinerators, which also have capacities in excess of 200 kilograms per hour, comply with legal standards governing such incinerators. Accordingly, both are slated to remain in operation.
③ Reduction of Use of Ozone-Damaging Chemical Substances DIC currently uses HCFC–141b gas in some of its expandable urethane resins. HCFC–141b was added to the list of designated ozone-damaging chemical substances as the consequence of a revision of the Law Concerning the Protection of the Ozone Layer in June 1994. DIC is developing an alternative to HCFC–141b gas and intends to cease use of the substance by 2004.
10
2002 ESH Activities
4. Safty Control of Chemical Substance
1 ）Preparation and Presentation of Safety Information on Chemical Substances The recently revised Labor Safety Hygiene Law and the Poisonous and Deleterious Substances Control Law, as well the newly established Law Concerning Reporting, etc. of Release to the Environment of Specific Chemical Substances and Promoting Improvements in Their Management, call for increased efforts by manufacturers to prepare and distribute product material safety data sheets (MSDSs) for chemical substances. DIC actively advocates the preparation and distribution of MSDSs that comply with new legislation and has finished modifying its own MSDS forms. DIC also prepares MSDSs in local languages for products sold in overseas markets. In fiscal 2001, the Company prepared 5,037 MSDSs in languages other than Japanese, an increase of approximately 700 from fiscal 2000.
2 ）Internal Assessment of Chemical Substances and Production Processes In fiscal 2001, DIC conducted 420 internal assessments of chemical substances and production processes, the results of which were incorporated into measures aimed at reducing chemical substance-related risks. With the aim of reinforcing chemical substance-related risk management, DIC has established an internal Chemical Substance Control Committee. The committee is charged with reducing related risks through such measures as promoting education regarding the appropriate use of chemical substances, the reduction of the volume of chemical substances used, the improvement of production processes and the development of alternative substances.
3 ）Quality Assurance The DIC quality assurance system allows the Company to immediately suspend production of a chemical substance and take appropriate steps, such as recalling products, should there be a danger of damage to the environment or the safety or health of employees or customers. No such incidents occurred in fiscal 2001.
5. Safety during Transportation DIC has established an emergency notification system to facilitate rapid responses to emergencies occurring during transportation of chemical substances. The system involves the distribution of transportation emergency response cards (“yellow cards”), which are given to drivers of container trucks, lorries and general mixed-freight transport trucks. In fiscal 2001, yellow cards were distributed to 98% of these drivers.
6. Green Procurement In January 2002, the parent company established internal standards for Green Procurement and asked its principal suppliers to conduct voluntary assessments using prepared questionnaires. Based on the results of these evaluations, procurement from suppliers meeting these standards accounted for 89% of total procurement in fiscal 2001. DIC will continue to encourage suppliers who do not meet these standards to implement changes and intends to achieve a 100% Green Procurement rate by the end of fiscal 2005. DIC's Green Procurement rate is calculated as: Total procurement from suppliers that internal Green Procurement standards Total procurement by procurement departments
×100
Table 4 DIC’s Green Procurement Standards (Suppliers must meet standards in both columns to qualify.) Activities A supplier must either ・have earned ISO14001 certification or have a management system in place and a definite schedule for applying for ISO 14001 certification or ・conduct its operations in accordance with the principal requirements for ISO 14001.
Materials Procured A supplier must
・supply materials that contain no prohibited substances, e.g., substances prohibited under the Labor Safety Hygiene Law or Type 1 substances prohibited under the Law Concerning the Examination and Regulation of Manufacture, etc. of Chemical Substances
As well, a supplier must either
・have a program in place for reducing emissions of substances harmful to the environment or ・recycle containers or otherwise contribute to environmental preservation.
7. Soil Analysis at Former Plant Sites As part of its efforts to reorganize its domestic manufacturing network, DIC closed its Amagasaki and Warabi plants in September 2001 and March 2002, respectively. Subsequently, DIC conducted soil analyses at both sites in accordance with the Ministry of the Environment’s guidelines for measuring soil and groundwater pollution, issued in 1999.
11
Responsible Care Care Responsible DAINIPPON INK AND CHEMICALS, INCORPORATED Development of Environment-Friendly Products DIC manufactures a number of environment-friendly products. For more information, visit the following page at DIC’s Web site: http://www.dic.co.jp/products/envfprod/index.html
1. Waterborne and Solvent-Free Products ・Water-dispersing urethane resin for use in molding strong, flexible capsules
VONDIC series
・Water-soluble can coatings ・Waterborne gravure ink for flexible packaging (surface printing)
MARINE GLOSS PE
・Waterborne gravure ink for flexible packaging (reverse printing)
ECOFINE; MARINE PLUS SK; HR
・Gravure ink for shrink labels
FINE LAP WPV
・Water-based adhesives
DICDRY WS series
2. Low- and NonVOC Products ・Intermediate offset ink containing aroma-free solvent (less than 1% aromatic ingredients)
New Champion F-Gloss
・100% vegetable oil-based offset ink
Naturalith 100
Soybean oil-based sheetfed offset ink
New Champion Naturalith 100
NonVOC sheetfed offset ink
Naturalith 100 POP
・Soybean oil-based news ink
News Zett Naturalith series
・Electron beam-curable top coating for decorative paper
Beam EB300 series
・Hybrid UV-curable ink requiring no special equipment
Daicure Hy-Bryte system
・Fluorine resin for wear-resistant coatings
Fluo-Net FEM series
・Urethane/acrylic composite polymer emulsion
VONCOAT CG series
・Solvent-free waterborne urethane ionomer resin
HYDRAN HW series
・Low formaldehyde-emission phenol resin adhesive
PHENOLITE
・Low-VOC decorative boards that improve room air quality
DIC Ambiente series (Esterboard; V-Shape Board)
Daicure Hy-Bryte system
12
New Champion Naturalith 100
2002 Development of Environment-Friendly Products
3. Recycling-Related Products ・Extrusion coating resin that facilitates recycling of paper
DIC THERM RP-100
・Artificial boards made from waste plastic
DIC WOOD
・Double-sided adhesive tape for molded plastic components
Daitac #8800CH
・Film and adhesive labels made with the same materials
Daiheart S series; Ecocycle series
as food packaging trays, which therefore do not have to be removed before recycling
4. Environment Protection ・Intermediate offset ink containing aroma-free solvent (less than 1% aromatic ingredients)
New Champion F-Gloss
・Halogen-free inflammable novolac resin
PHENOLITE 7050 series
・Environment-friendly nonchlorofluorocarbon rigid polyurethane spray foam
HIPROX RP8000
・Soil control system using oxygen-free water
REVITAR
・Sheet heater for pavement, floor and roof
DAIELEC Heater
・Barium-free red monoazo pigment
SYMULER RED 3119
5. Waste Reduction ・Thick sheet molding compound (SMC) that facilitates 50% reduction of waste film
GMC series
6. Fume Reduction ・ Low-fume liquid urethane water-resistant coatings
Flatone (for flat surfaces); DIC Urethane series (primer)
7. Timber Resource Conservation Products ・Lightweight rigid polyurethane sandwich panel for truck beds
Decorative surface: PET specialty resin sheet Adhesive layer Base: Medium-density fiberboard (MDF) (EO Evolutionary Computation Framework-compatible) or composite board (FcO-compatible)
DIC Ambiente series (Esterboard)
DIC U-Panel series
Decorative surface: urethane resin sheet Adhesive layer Base: MDF (EO Evolutionary Computation Framework-compatible) or composite board (FcO-compatible)
DIC Ambiente series (V-Shape Board)
13
Responsible Care Care Responsible DAINIPPON INK AND CHEMICALS, INCORPORATED ESH in Research and Development and New Businesses 1. R&D 1 ）Safety Training for Employees In line with its Safety in Technology and Research Policy, DIC provides general safety and workplace safety training to employees.
2 ）Development of Environment-Friendly Products DIC is also actively committed to the development of environment-friendly products. Achievements to date include emulsions that uses water as a diluent, products with reduced solvent content and decorative boards for residential interiors containing almost no substances identified as causing increased VOC concentrations in rooms. In fiscal 2001, DIC launched a new intermediate offset ink containing aroma-free solvent, while Naturalith 100—a 100% vegetable oil-based offset ink containing no VOCs developed in a cooperative project with electric and information equipment manufacturers—was awarded the JCIA’s Technology Prize. Principal environment-friendly products manufactured by DIC are listed on page 12–13 of this report.
2. New Businesses Prior to preparing its capital investment plan for fiscal 2001, DIC conducted an advance safety assessment aimed at enhancing the safety and reliability of management systems and reducing the margin for human error. Plants were subjected to process safety management (PSM) procedures, while new R&D centers were designed to be energy-efficient and equipped with organic solvent and exhaust gas processing and rainwater recycling facilities.
ESH in International Operations DIC provides extensive Responsible Care training to managers assigned to overseas affiliates prior to sending them abroad. English-language versions of DIC’s Safety Procedures for Static Electricity and Testing and Principles of Safe Conduct: Procedures and Attitudes for a Safe Workplace have been distributed to affiliates in Southeast Asia. The DIC Central Research Laboratories provide safety information on chemical substances to the Company’s R&D facilities overseas, thereby ensuring maintenance of the highest ESH standards.
ESH in International Transactions In addition to adhering to the rules outlined in its Safety Management for International Trade Manual, DIC has prepared a checklist for employees traveling overseas on business to prevent the illegal export of products, regulated substances and technologies. DIC also keeps abreast of information on trafficking in prohibited substances and has established an internal mechanism to ensure adherence with international regulations.
14
2002 Interaction with the Local Community Copies of DIC’s Responsible Care Report 2001 were distributed to plants and the DIC Central Research Laboratories, together with the Principle and Policy for the Environment, Safety and Health, for internal use and for handing out to visitors to the Company. The report can also be viewed by visiting DIC’s Web site at http://www.dic.co.jp/eng/rc/index.html. During the period, DIC’s Chiba Plant participated in the Japan Responsible Care Council’s fiscal 2001 Responsible Care Conference as a representative of Chiba Prefecture. DIC invited local residents to visit its plants throughout Japan in an effort to promote effective communication. As well, DIC employees volunteered their time in the community in a variety of capacities, including serving as automobile safety and sports instructors and participating in local clean-up efforts.
DIC Plants / R&D Center
Ishikari Plant
Gunma Plant
Tatebayashi Plant
Saitama Plant
Kashima Plant
Tokyo Plant
Chiba Plant
DIC Central Research Laboratories
Mikawa Plant
Komaki Plant
Yokkaichi Plant
Shiga Plant
Ishikari Plant Mikawa Plant Komaki Plant Shiga Plant Suita Plant
Suita Plant
Gunma Plant Tatebayashi Plant Saitama Plant DIC Central Research Laboratories
Sakai Plant
Fukuoka Plant Sakai Plant
Kashima Plant Tokyo Plant Chiba Plant Yokkaichi Plant
Fukuoka Plant
15
Responsible Care Care Responsible DAINIPPON INK AND CHEMICALS, INCORPORATED Introducing the Mikawa Plant Outline The Mikawa Plant is located at the mouth of the Tedori River, which flows from Mt. Hakusan in the Kirigamine range, and close to the Komatsu coast, which is considered one of Japan’s most beautiful coastlines. The plant, which commenced operations in 1959, represents Ishikawa Prefecture’s first successful bid for a manufacturing facility and remains the only synthetic resin plant on the Japan Sea coast. The plant currently has a total floor space of approximately 140,000 square meters and employs 210 people.
Responsible Care Activities at the Mikawa Plant
Takeo Nakamura
Hiroyuki Furukawa
Yasuzo Nakatani
General Manager, Mikawa Plant
General Manager,
Manager in charge of environment and safety management,
Environment, Safety and Quality Control Department,
Mikawa Plant
1 ) Labor Accident Prevention
Mikawa Plant
Efforts to prevent labor accidents at the Mikawa Plant center on stringent observation of three key principles of prevention; employee education involving examination of past emergency situations and their causes; strict checks by general managers and managers; and participation in a DIC Group safety committee. In May 2002, the plant marked 29 consecutive labor accident-free years and 8.1 labor accident-free hours. The Mikawa Plant has also won the Minister of Health, Labour and Welfare’s First Prize (Safety) twice, a national record. 2 ) Industrial Waste Reduction The Mikawa Plant’s industrial waste reduction program focuses on taking steps to minimize output and recycling waste using subcontractors. While the plant has made notable progress on many fronts, measures to reduce the amount of surplus contaminated sludge from wastewater processing facilities disposed of as landfill have been less successful than anticipated. Accordingly, the plant has begun recycling surplus contaminated sludge into fertilizer and fuel and is working to lower output. Through these and other efforts, Mikawa Plant aims to achieve zero emissions by fiscal 2010. The plant’s recycling rate in fiscal 2001 was 65.1%. 3 ) Lower Energy Consumption With the closure of its formalin facility, which played a key role in heat recovery, the Mikawa Plant established an Energy Efficiency and Waste Management Committee and has switched its emphasis to installing energy-efficient facilities and implementing innovative ideas for lowering energy consumption. The plant is also stepping up patrols and otherwise enhancing its monitoring of consumption. In fiscal 2003, the plant plans to introduce a cogeneration system. 4 ) Safety Control of Chemical Substances/Employee Training Because it handles self-reactive substances with low boiling and ignition points, the Mikawa Plant conducts on-site employee training using MSDSs as materials and implements measures aimed at improving the working environment for its employees. These include modifying procedures to, for example, eliminate the causes of accidents. In fiscal 2001, the plant’s collection rate for MSDSs was 91% for raw materials and 100% for finished products. 5 ) Compliance with ISO 14001 The Mikawa Plant obtained ISO 14001 certification in fiscal 1997, together with the Kansai Polymer Plant (Sakai) and the Amagasaki Plant, and in August 2000 completed its first inspection for renewal. In line with DIC’s Principle and Policy for the Environment, Safety and Health, the Mikawa Plant is committed to safety, a low environmental burden, the reuse of resources and the reduction of energy consumption through the full life cycle of chemical products, from development to disposal. The plant has established an internal auditing system to ensure this commitment is met. 6 ) Interaction with the Community The Mikawa Plant is close to the Hokuriku Line’s Komatsu Station, a center of community life. Accordingly, maintaining good relations with local residents is essential. To this end, the plant has installed state-of-the-art exhaust emission reduction equipment and incinerators. As well, the plant has contracted 12 households in the immediate vicinity to monitor air quality and set up a quick-response system to ensure complaints about air quality are addressed promptly and effectively. A plant representative visits these 12 households monthly to gather information. Mikawa Plant employees participate actively in a variety of community activities, including clean-up efforts, the local traffic safety council, fire prevention and safety committees and the town’s chamber of commerce.
16
Overview of Mikawa plant
Planting fir tree seedlings as part of a local greening program
2002 History of DIC’s Environment and Safety Program 1973
1974
Environment and Safety Response Department established under direct supervision of DIC’s President
Year
Recipient
Award
1973
Amagasaki Plant
Effort Prize (Minister of Labor)
Internal safety audit conducted
1974
Warabi Plant
Effort Prize (Minister of Labor)
1976
Warabi Plant
First Prize (Hygiene) (Minister of Labor)
1978
Mikawa Plant
Progress Prize (Minister of Labor)
Environment and Safety Management Regulations and Working Regulations for Interim Countermeasures Department established Inspection of environment and safety precautions at major plants undertaken
1977
Large-scale waste incinerator installed at Chiba Plant
1979
Procedures for Using New Chemicals established Questionnaire on Characteristics of Chemicals established
1982
Guidelines for Training Inexperienced Workers ( New Employees) established
1983
Professional sanitary guidance qualifications made mandatory for all managementlevel personnel
1984 1985
Environment and Safety Awards Received by DIC
Sakai Plant
Progress Prize (Minister of Labor)
1979
Hokkaido Plant
Effort Prize (Minister of Labor)
Mikawa Plant
Effort Prize (Minister of Labor)
1981
Tokyo Plant
Effort Prize (Minister of Labor)
1982
Mikawa Plant
First Prize (Safety) (Minister of Labor)
1984
First Prize (Hygiene) (Minister of Labor)
Mikawa Plant
First Prize (Hygiene) (Minister of Labor)
Inspection of environment and safety precautions at branch offices, subbranches and sales offices launched
1987
Sakai Plant
First Prize (Hygiene) (Minister of Labor)
1989
Amagasaki Plant
First Prize (Hygiene) (Minister of Labor)
5 S Procedures and Attitudes for a Safe Workplace and Examples of Emergency Situations published
1991
Sakai Plant
Progress Prize (Minister of Labor)
1992
Chiba Plant
Effort Prize (Minister of Labor)
Sakai Plant
Top Hazardous Substance Operation Commendation
Chiba Plant
Top Plant for High-Pressure Gas Safety Commendation
Mikawa Plant
Top Hazardous Substance Operation Commendation
1987
Campaign to identify potential accidents launched
1988
Environment and Safety Guidelines for the R&D Department published Environment and Safety Management Regulations revised to include section on global environmental preservation
(Commissioner, Fire Defense Agency) 1993
(Minister of International Trade and Industry) (Commissioner, Fire Defense Agency) Safety Effort Award, JCIA 1994
Environment and Safety Philosophy formulated Accident-free year achieved for entire Company
Voluntary Long-Term Environment and Safety Plan formulated
Top Hazardous Substance Operation Commendation
Sakai Plant
First Prize (Safety) (Minister of Labor)
Warabi Plant
Top Hazardous Substance Operation Commendation
Saitama Plant
Progress Prize (Minister of Labor)
Nagoya Plant
Effort Prize (Minister of Labor)
Chemical substance safety information officer appointed in each division
Amagasaki Plant
Top Hazardous Substance Operation Commendation
Various commemorative events held to mark 20th year of DIC’s environment and safety program
Nagoya Plant
Top Hazardous Substance Operation Commendation
Public pledge to uphold principles of Responsible Care announced by DIC in its role as a founding member of Japan's Responsible Care movement
Fukuoka Plant
Special Commendation (JCIA)
Mikawa Plant
Top Plant for High-Pressure Gas Safety Commendation
Procedures and route for reporting and communicating instructions in the event of an accident established for domestic and overseas affiliates
Tokyo Plant
Top Hazardous Substance Operation Commendation
The Aftermath of the Great Hanshin-Awaji Earthquake published, chronicling conditions following the disaster
Tokyo Plant
Safety Award (JCIA)
Fukuoka Plant
Top Hazardous Substance Operation Commendation
Ishikari Plant
Top Hazardous Substance Operation Commendation
Suita Plant
Top Hazardous Substance Operation Commendation
Guidelines for Crisis Management in the Event of an Accident established
Responsible Care audit system established 1996
Effort Prize (Minister of Labor)
Chiba Plant
(Commissioner, Fire Defense Agency) 1996
Guidelines for Preventing Accidents Caused by Static established
1995
Suita Plant
(Commissioner, Fire Defense Agency) 1995
Guidelines for Preparing MSDSs established 1993
First Prize (Hygiene) (Minister of Labor)
Hokkaido Plant
Guidelines for Implementing Management Directives on Key Environment and Safety Issues published
1992
Effort Prize (Minister of Labor)
Tokyo Plant
1986
Campaign to reinforce 5 S Procedures and Attitudes for a Safe Workplace launched following several accidents
1990
Sakai Plant
(Commissioner, Fire Defense Agency) (Commissioner, Fire Defense Agency) 1997
(Minister of International Trade and Industry) (Commissioner, Fire Defense Agency) 1998
(Commissioner, Fire Defense Agency)
Guidelines for Selling Chemical Products established
(Commissioner, Fire Defense Agency)
Safety and Quality Control Supervisor appointed at sales office Responsible Care Report 1996, DIC’s first Responsible Care report, published
1999
(Commissioner, Fire Defense Agency)
ISO 14001 certification obtained by Kashima Plant from Japan Quality Assurance Association
Kansai Polymer Plant Sakai Plant
Safety Effort Award (JCIA)
1997
Sakai, Amagasaki, Mikawa, Chiba, Tokyo, Saitama, Yokkaichi, Gunma and Komaki plants obtain ISO 14001 certification
Nagoya Plant
Progress Prize (Minister of Labor)
1998
PSM Guidelines published First edition of Examples of Accidents and third editions of Examples of Emergency Situations and Procedures and Attitudes for a Safe Workplace published Suita, Warabi and Nagoya plants obtain ISO 14001 certification
1999
PRTR chemical emission levels announced
2000 Registration and monitoring of chemical emissions are modified in compliance with new PRTR system
2000 2001
Mikawa Plant
Safety Award (JCIA)
Mikawa Plant
First Prize (Safety) (Minister of Health, Labour and Welfare)
DIC
Chairman’s Award (Japan Industrial Safety and Health Association)
Saitama Plant
Top Hazardous Substance Operation Commendation (Commissioner, Fire Defense Agency) First Prize (Safety) (Minister of Health, Labour and Welfare)
Environment-related costs and investments published in line with standards for environmental accounting issued by Japan’s Environment Agency 2001
Emission volumes for “priority” PRTR chemicals, i.e., those for which emissions exceed 10 tons, published
17
Printed on nonwood paper (50% bagasse/50% recycled paper fibers) using DIC’s Naturalith 100 vegetable oil-based offset ink
“Responsible Care” refers to activities pledged and carried out by companies that manufacture and/or handle chemical substances with the aim of protecting the environment, safety and health and to the implementation and continual revision of measures to accomplish this aim throughout the full life cycle of chemical products, from development and production through distribution and use to final consumption and disposal.
Enviroment, Safety & Quality Management Department DAINIPPON INK AND CHEMICALS, INCORPORATED DIC Building, 7-20, Nihonbashi 3-chome, Chuo-ku, Tokyo 103-8233, Japan PHONE: +81(3)5203-7753 FAX: +81(3)3278-0253 URL: http://www.dic.co.jp/eng/rc/index.html
2002
Dainippon Ink and Chemicals, Incorporated Corporate Headquarters : DIC Building, 7-20, Nihonbashi 3-chome, Chuo-ku, Tokyo, Japan 103-8233 Date of Foundation : February 15, 1908 Date of Incorporation : March 15, 1937 Paid-in Capital : ¥82,423 million (As of March 31, 2002) Number of Employees : 5,082 (As of March 31, 2002) Net Sales : ¥370,381 million (Fiscal 2001)
CONTENTS A Message from the President
1
Principle and Policy for the Environment, Safety and Health
2
ESH Activities
5
1. Environmental Costs and Safety- and Health-Related Expenses and Investments 2. Safety and Health Record 3. Environmental Load Reduction 4. Safety Control of Chemical Substances 5. Safety during Transportation 6. Green Procurement 7. Soil Analysis at Former Plant Sites
Development of Environment-Friendly Products
12
ESH in Research and Development and New Businesses
14
ESH in International Operations
14
ESH in International Transactions
14
Interaction with the Local Community
15
DIC Plants / R&D Center
15
Introducing the Mikawa Plant
16
History of DIC’s Environment and Safety Program
17
Environment and Safety Awards Received by DIC
17
Responsible Care Care Responsible DAINIPPON INK AND CHEMICALS, INCORPORATED
A Message from the President Dainippon Ink and Chemicals, Incorporated (DIC), dedicates itself to being a creative and distinctive organization capable of innovating products that enhance the lives of people around the world. In line with this philosophy, we have cultivated operations in our core businesses, notably graphic arts materials and polymers and related products, and currently have subsidiaries and affiliates in 64 countries around the world. We recognize that care for the environment, safety and health (ESH) is fundamental to management and seek to incorporate these concerns in all aspects of our activities. In 1992, we formulated and publicly announced an official principle and policy recognizing the importance of care for the environment, safety and health. The principle and policy were reaffirmed in 1995, when we unveiled and began implementing our Responsible Care program as one of the 74 founding companies of the Japan Responsible Care Council. Since then, we have made substantial progress on several fronts, including reducing environmental load, lowering consumption of energy and resources, minimizing the generation of industrial waste, improving control of chemical substances and eliminating accidents at our plants. Fiscal 2001, ended March 31, 2002, brought a number of notable achievements. For example, efforts to revamp production processes contributed to a reduction in energy consumption of 2.6% per unit (ton) of production from fiscal 2000, and 16% from fiscal 1990. Efforts to reduce environmental load led to a decrease in carbon dioxide emissions of 2.5% from the previous fiscal year, or 22% from fiscal 1990. We also slashed the volume of waste disposed of as landfill 30%, or 57% from 1990. In the area of product development, we introduced Naturalith 100, a series of 100% vegetable oil-based offset inks containing no volatile organic compounds (VOCs) and low-VOC decorative boards that improve room air quality. Naturalith 100 was honored with the Japan Chemical Industry Association (JCIA) Technology Prize for 2002. The DIC Group will continue to address key tasks to promote sustained growth and development, harmony with the environment and awareness of recycling, as well as to earn the trust of people worldwide. I am pleased and proud to present DIC’s Responsible Care Report 2002, which summarizes the results of our ESH activities during fiscal 2001. We welcome and appreciate comments or advice from readers regarding our activities and the content of this report. September 2002
President and CEO
1
Responsible Care Care Responsible DAINIPPON INK AND CHEMICALS, INCORPORATED Principle and Policy for the Environment, Safety and Health [Principle]
As a responsible corporate citizen, Dainippon Ink and Chemicals, Incorporated (DIC), recognizes that care for the environment, safety and health (ESH) is fundamental to the management of the Company. DIC is committed to the concept of sustainable development and contributes to society by creating environmentally sound products and technology. [Policy] 1.
We establish ESH-related objectives and targets and pursue continual progress.
2.
We comply with laws, regulations and agreements relevant to ESH.
3.
We consider the ESH implications of each of our products throughout their life cycles in accordance with the ideals of Responsible Care.
4.
We instill in our employees a thorough understanding of this fundamental Principle and Policy.
5.
We organize our operations so as to promote the safeguarding of the environment, safety and health and conduct audits to monitor progress throughout the Company.
6.
We ensure that operations are conducted safely and materials are handled properly. We try to prevent environmental pollution and avoid affecting the environment negatively by recycling waste, conserving energy and other resources and using materials that are environmentally friendly.
7.
We place the utmost importance on ESH-related considerations at all stages of the new product planning and production process.
8.
We promote safety by providing customers with detailed instructions on the proper use and handling of all products.
9.
In our overseas activities, we conduct environmental impact assessments and strictly observe local ESH regulations. In the absence of such regulations, we work with local officials and our business partners to develop environmental safeguards. We also follow this procedure when dealing with toxic materials, applying the same stringent standards for their handling as required in Japan. In addition, we promote the transfer of technology and know-how related to environmental protection.
10.
We provide the public and appropriate authorities with ample information about our products and business activities so that they may have an accurate understanding of our efforts to promote health, safety and environmental protection. The above Principle and Policy shall be available to all employees and to the general public. It is our goal that this Principle and Policy be followed at all DIC Group companies.
Established April 1, 1992 Revised February 1, 1996
2
2002 DIC’s Responsible Care System 1. Responsible Care Organization (Environment, Safety and Quality Management) DIC has appointed an executive charged with setting up an Environment, Safety and Quality Management Department and with overseeing Responsible Care activities.
XXXX Branch Office
XXXX Division
XXXX Office
Responsible Care Department
President
Safety and Quality Management Supervisor
XXXX Office Safety and Quality Management Supervisor XXXX Branch Office Safety and Quality Management Supervisor
Director in charge of Responsible Care XXXX Division
Safety and Quality Management Supervisor
DIC Central Research Laboratories Environment, Safety and Quality Management Department XXXX Plant
Domestic subsidiaries and affiliates Overseas subsidiaries and affiliates
Environment, Safety and Quality Management Department XXXX Plant Environment, Safety and Quality Management Section
Fig. 1 DIC’s Environment, Safety and Quality Management Organization
2. Responsible Care Organization DIC’s Responsible Care organization comprises two bodies, which are responsible for decision making and monitoring activities, respectively.
１）Decision-Making System
Environment and Safety Conference As the principal decision-making body for Responsible Care activities, DIC has established the Environment and Safety Conference at its head office. This conference includes the executive vice president, relevant directors, executives in charge of Responsible Care at each DIC plant and general managers of relevant business divisions at the head office.
3
Responsible Care Care Responsible DAINIPPON INK AND CHEMICALS, INCORPORATED DIC’s Responsible Care System
Divisional System At each DIC plant and research facility, an Environment and Safety Committee has been established and environment, safety and quality control personnel assigned. DIC has also assigned a Safety and Quality Management Supervisor to each sales office. All of DIC’s principal plants have obtained ISO 14001 certification, the International Organization for Standardization’s global benchmark for environmental management systems, allowing them to measure Responsible Care efforts against internationally accepted criteria. Plants and the fiscal year in which each obtained ISO 14001 certification are: Fiscal 1996 Fiscal 1997 Fiscal 1998
Kashima Plant Sakai Plant; Amagasaki Plant; Mikawa Plant; Chiba Plant; Tokyo Plant, Saitama Plant; Yokkaichi Plant; Gunma Plant; Komaki Plant Suita Plant; Warabi Plant; Nagoya Plant
２）Internal Audit System DIC’s internal Responsible Care audit system is overseen by the Responsible Care Review Committee and includes periodic audits by top executives from the head office as well as internal audits.
Responsible Care Review Committee The Responsible Care Review Committee comprises directors and general managers of relevant business divisions of the parent company and monitors the Responsible Care activities of each plant on an annual basis.
Audits by Top Executives Inspection teams consisting of the general manager and staff of the parent company’s Responsible Care Department and led by top executives monitor the Responsible Care activities of each plant through on-site audits.
Internal Audits Individual plants, laboratories and offices conduct periodic internal audits. Board of Managing Directors/Board of Directors
Responsible Care Review Committee Audits by top executives
President
Environment and Safety Conference
Environment, Safety and Quality General Managers’ and Managers’ Committee Safety and Quality Management Supervisors' Committee Plant Environment and Safety Committees (RC Committees) DIC Central Research Laboratories’ Environment and Safety Committee (RC Committees)
4
Fig. 2 DIC’s Responsible Care Organization
Internal audits Internal branch and sales office audits Audits of domestic and overseas subsidiaries and affiliates
2002 ESH Activities 1. Environmental Costs and Safety- and Health-Related Expenses and Investments 1 ）Environmental Costs In line with the Preparation for Establishment of an Environmental Accounting System (2000 Report), published by Japan’s Environment Agency, we have calculated amounts for environment-related expenses and investments in fiscal 2001. Environment-related expenses totaled ¥8,958 million, while investments amounted to ¥1,191 million. Of total environment-related expenses, 40% was accounted for by measures to prevent pollution and protect the environment, 53% by environmental R&D, 4% by environmental control measures and the remaining 3% by other measures. Other measures 3％ Environmental control measures 4 ％
Measures to prevent pollution and protect the environment 40％
Environmental R&D 53％
Fig. 3 Breakdown of Fiscal 2001 Environmental Expenses Millions of yen
Environmental Costs Category
Scope
1. Costs incurred through activities aimed at minimizing environmental load generated within the business area through production and sales activities (costs within the business area)
Investments
Expenses
Costs related to the preservation of air and water quality, maintenance or improvement of waste disposal and recycling activities
￥517
￥3,546
Costs related to the preservation of air and water quality
350
1,811
･ Operating/maintenance expenses related to activities aimed at curbing air pollution (310), global warming (180), water pollution (1,010), soil pollution prevention expenses (3) and other expenses ･ Investments in air pollution prevention activities (227), water pollution prevention activities (120) and other investments
(a) Pollution prevention and environmental protection costs
Costs related to the maintenance or improvement of energy consumption and internal and external waste disposal
167
1,736
･ Operating/maintenance expenses for activities aimed at reducing energy and resource consumption (530), water consumption (2) and waste disposal (1,090), expenses related to the obligatory recycling of used merchandise (0.2) and other expenses
(b) Resource recycling costs
･ Investments in activities aimed at reducing energy consumption (120), waste disposal activities (50) and other investments
2. Environmental costs related to management activities (management activity costs)
3. Environmental costs related to technological activities (technological activity costs) (Note 2)
Costs related to environmental and safety promotion and education; environmental management and auditing related to acquisition of ISO14001 certification ･ Personnel/administrative expenses (250), ISO 14001 maintenance expenses (12), environmental load measurement expenses (64) and other expenses Expenses and investments related to the development of products that reduce environmental burden (including personnel expenses)
( Note 1)
368
665
4,796
9
175
0
73
￥1,191
￥8,958
Costs of plant and office greening programs and shared costs
4. Environmental costs related to social activities (social activity costs)
･ Internal maintenance expenses (55), fees to external organizations (78) and other expenses ･ Investments in greening programs (8)
5. Costs related to damage inflicted on the environment (environmental damage costs)
Environmental clean-up and other expenses ･ Levies on lake development (65) and other expenses
Total
Notes: 1. The investment portion of management activity costs is included in costs within the business area. 2. Technological activity costs are costs related to the development of products that reduce environmental burden and include R&D costs for new products as well as the improvement/customization of existing products.
5
Responsible Care Care Responsible DAINIPPON INK AND CHEMICALS, INCORPORATED
millions of yen Category
Composition
Expenses
Investments in facilities to reduce environmental burden and lower energy and resource consumption; other investments
Environment-related facility investments Percentage of total facility investments
￥1,191
6.2% Investments related to environmental conservation technologies and the development of products that reduce environmental burden
Environment-related technology costs Percentage of total technology costs
5,461
19.0%
See pages 8–11 for detailed data on the impact of DIC’s environmental conservation measures since fiscal 1990. millions of yen Economic Effects of Environmental Conservatioin Measures Category
Expenses
￥390
Income earned by waste recycling
270
Treatment cost reduction through waste recycling Cost reduction through energy conservation
229 ￥889
Total
Table 2
Impact of Measures to Protect the Environment Impact of Measures to Protect the Environment Environmental Load Index
1. Impact of environmental protection measures within the business area
· CO2 emissions (calculated in tons of carbon) per unit of production
78.8% (fiscal 1990=100)
· SOx emissions per unit of production
25.5% (fiscal 1990=100)
· NOx emissions per unit of production
70.7% (fiscal 1990=100)
· COD emissions per unit of production
60.0% (fiscal 1990=100)
· Energy used (calculated in volume of crude oil used) per unit of production
84.4% (fiscal 1990=100)
· Emissions of solid wastes disposed of through burial by external companies
43.1% (of the fiscal 1990 level)
· Fees paid for the disposal of solid wastes through burial by external companies (fiscal 2001 actual payment basis) were ¥830 million lower than in fiscal 1990. (Note 1) · Emissions of Pollutant Release and Transfer Register (PRTR) chemicals were 76.1% of the fiscal 1999 level. (Note 2)
2. Impact of environmental protection upstream and downstream measures
· The reduction in CO2 emissions realized as a result of modal shifts was 35.8% higher in fiscal 2001 than in fiscal 1999. (Note 3)
Notes: 1. The comparison of fees paid for the disposal of solid wastes through burial by external companies (fiscal 2001 actual payment basis) was calculated by subtracting the fiscal 2001 total from the fiscal 1990 total. 2. Figures represent emissions of PRTR chemicals based on a revised list of target chemicals that went into effect in fiscal 2001 and is retroactive to fiscal 1999. (The new list encompasses 480 chemicals, of which DIC uses 120.) 3. Calculations are based on standards set forth by the Japan Federation of Freight Industries in its Report on Survey of Modal Shifts. The aim is to compare how much greater a reduction in CO2 emissions was realized through the use of large-scale transport modes in fiscal 2001 than in fiscal 2000.
２）Safety- and Health-Related Expenses and Investments Safety- and health-related expenses in fiscal 2001 totaled ¥72.0 billion, while safety- and health-related investments were ¥36.1 billion. Pertinent safety and health management activities accounted for 56% of expenses, while fees paid to outside firms for safety data-related tests represented 7%, safety and fire prevention measures totaled 19% and specific safety and health-related measures amounted to 18%. Safety and fire prevention measures 1 9 %
Safety and health management activities 56%
Fees paid to outside firms for safety data-related tests 7 %
Specific safety- and health-related measures 18%
6
Fig. 4 Breakdown of Safety- and Health-Related Expenses
2002 ESH Activities
2. Safety and Health Record
DIC was honored to receive several awards during fiscal 2001 in recognition of its superb safety record and accumulated experience in ensuring employee safety. DIC: Chairman’s Award (Japan Industrial Safety and Health Association) Saitama Plant: Top Hazardous Substance Operation Commendation (Commissioner, Fire Defense Agency) First Prize (Safety) (Minister of Health, Labour and Welfare)
During fiscal 2001, two accidents resulting in an absence of more than one day were reported at DIC plants, one more than in the previous fiscal year. The labor accident frequency rate for the period was 0.52 and the labor accident severity rate was 0.093, compared with 0.12 and 0.010, respectively, in fiscal 2000. Figures 5 and 6 show DIC’s labor accident frequency and severity rates from fiscal 1990 through fiscal 2001. Labor accidents are defined by DIC and the Japan Chemical Industry Association(JCIA) as accidents resulting in a suspension of operations for more than one day and by the chemical industry as accidents resulting in a suspension of operations for more than four days.
DIC
JCIA
Chemical industry
Frequency
1.5 1.0 0.5 0 1990
1991
1992
1993
1994
1995
1996
1997
1998
1999
2000
2001 Fiscal year
Fig. 5 Labor Accident Frequency Rate
DIC
JCIA
Chemical industry
0.25
Severity
0.20 0.15 0.10 0.05 0.00 1990
1991
1992
1993
1994
1995
1996
1997
1998
1999
2000
2001 Fiscal year
Fig. 6 Labor Accident Severity Rate
The first of the two accidents in fiscal 2001 that involved injuries resulting in a suspension of work happened when an employee backed into a piece of equipment on a production line, causing broken ribs. The second accident also involved broken ribs, in this case sustained when an employee was trapped between two pieces of equipment. Both injuries were treated and healed, resulting in no lasting impairment. Note: Labor accident frequency rate = Number of accidents and injuries due to labor accidents per one million hours of labor Example: A labor accident frequency rate of 1.0 corresponds to one accident per year in a workplace with 500 employees. Labor accident severity rate = Number of work hours lost per one thousand hours of labor Example: A labor accident severity rate of 0.1 corresponds to 100 work hours lost per year in a workplace with 500 employees. These terms were developed by the JCIA, which has 197 member companies. “Chemical industry,” as used in these figures, is a classification used by the Ministry of Health, Labour and Welfare for reporting labor accident statistics.
7
Responsible Care Care Responsible DAINIPPON INK AND CHEMICALS, INCORPORATED ESH Activities
3. Environmental Load Reduction 1 ） Emissions of CO2, SOx, NOx and COD
Emissions of CO2 have declined significantly thanks to several factors, including improvements in production processes and the introduction of cogeneration systems at principal plants between fiscal 1990 and fiscal 1998, and to ongoing efforts to reduce energy consumption. The following four figures index DIC’s emissions of carbon dioxide (CO2), sulfur oxide (SO x ), nitrogen oxide (NOx) and chemical oxygen demand (COD) per unit (ton) of production from fiscal 1990 through fiscal 2001 (fiscal 1990=100).
Emission Index
Thousands of tons
100 90
100
Goal
80
80 70 60
60
50 40
40
30 20
20
10
0
Emission Volume
Emission Volume
120
0
1990
1991
1992
1993
1994
1995
1996
1997
1998
1999
2000
2001
2010 Fiscal year
Fig. 7 CO2 Emission Index (fiscal 1990=100)
DIC’s SO x, NO x and COD indices remain favorable and stable and are well below legislated or stipulated levels.
Emission Index
120 100 80 60 40 20 0 1990
1991
1992
1993
1994
1995
1996
1997
1998
1999
2000
2001 Fiscal year
2000
2001 Fiscal year
Fig. 8 SOx Emission Index (fiscal 1990=100)
Emission Index
120 100 80 60 40 20 0 1990
1991
1992
1993
1994
1995
1996
1997
1998
1999
Fig. 9 NOx Emission Index (fiscal 1990=100)
8
2002 ESH Activities Emission Index
120 100 80 60 40 20 0 1990
1991
1992
1993
1994
1995
1996
1997
1998
1999
2000
2001
Fiscal year
Fig. 10 COD Emission Index (fiscal 1990=100)
２）Energy Consumption Energy consumption peaked in fiscal 1993, owing to the construction of a new plant early in 1990 and the start of operations at the plant in 1993. Between fiscal 1996 and fiscal 1998, DIC installed cogeneration systems at three plants. In fiscal 1999, the Company installed highly productive manufacturing facilities utilizing new energy technologies at the Yokkaichi Plant. As a consequence, energy consumption per unit (ton) of production at the plant decreased approximately 40% in fiscal 1999. The new facilities, together with ongoing efforts to reduce energy consumption, have also contributed to a steady decrease since fiscal 2000.
Consumption Index
Thousands of tons
160 140
100
Goal
80
120 100
60
80
40
60 40
20
20
0
0
1990
1991
1992
1993
1994
1995
1996
1997
1998
1999
2000
2001
Consumption Volume
Consumption Volume
120
2010 Fiscal year
Fig. 11 DIC’s Energy Consumption per Unit (ton) of Production from Fiscal 1990 through Fiscal 2001 (fiscal 1990=100).
３） Industrial Waste Figure 12 illustrates the annual volume of industrial waste generated by DIC that has been disposed of as landfill by external companies since fiscal 1990. In line with its commitment to helping promote a more recycling-oriented society, DIC has set forth an industrial waste disposal goal for fiscal 2010 of 5% below the fiscal 1999 level. To this end, in fiscal 2001 DIC established a special project team. As a consequence, the volume of industrial waste generated by DIC disposed of as landfill in fiscal 2001 declined approximately 30% from fiscal 2000.
Volume of Industrial Waste Disposed of as Landfill
Tons/year
16,000 14,000 12,000
Goal
10,000 8,000 6,000 4,000 2,000 0
1990
1991
1992
1993
1994
1995
1996
1997
1998
1999
2000
2001
2010
Fiscal year
Fig. 12 Volume of Industrial Waste Disposed of as Landfill by External Companies
9
Responsible Care Care Responsible DAINIPPON INK AND CHEMICALS, INCORPORATED ESH Activities
４） Polluting Chemical Substance Emissions ① PRTR Chemicals
DIC used 120 of the 480 PRTR chemicals in fiscal 2001. Total emissions of these chemicals during the period amounted to 652 tons, down 13.0% from 749 tons in fiscal 2000. This reduction is attributable to the installation of solvent recovery facilities and the integration of plants, which boosted operating rates for recovery facilities at remaining plants.
t/y 2,500
Emissions of Polluting Chemical Substances
In fiscal 2001, JCIA increased the number of PRTR chemicals—polluting chemical substances for which it requires its member companies to register and monitor emissions—to 480, from 284. As well, JCIA lowered the minimum annual emission volume for PRTR qualification from 10 tons to five tons for most PRTR chemicals and 0.5 tons for those that are carcinogenic.
Based on previous JCIA standards (284 chemicals) Based on current JCIA standards (480 chemicals)
2,000 1,500 1,000 500 0
1996
1997
1998
1999
2000
2001
Fiscal year
Fig. 13 Emissions of Polluting Chemical Substances
Table 3
Figure 13 shows DIC’s emissions of all PRTR chemicals since fiscal 1996. Table 3 shows fiscal 2001 emissions of those PRTR chemicals for which emission levels exceeded 10 tons. The Ministry of Economy, Trade and Industry has issued guidelines for the 12 PRTR chemicals it has designated “ priority ” chemicals, in line with which manufacturers conduct voluntary atmospheric contamination control programs. In fiscal 2001, DIC used six of these “priority” chemicals, the same number as in fiscal 2000, while its emissions of these six chemicals totaled 13 tons, down 13% from the previous term. Note: PRTR chemicals encompass polluting chemical substances for which JCIA requires companies to register and monitor emission levels and chemicals targeted by the Law Concerning Reporting, etc. of Release to the Environment of Specific Chemical Substances and Promoting Improvements in Their Management.
PRTR Chemicals with Emissions in Excess of 10 Tons in Fiscal 2001 Chemical
Volume Manufactured /Used
Volume Emitted
Ethyl acetate
13,725
106
Toluene
13,083
96
Xylene
8,957
81
Methyl ethyl ketone
9,765
78
Methyl ethyl alcohol
4,086
58
23,665
33
N–Methylpyrrolidone
162
23
HCFC–141b (under different names)
379
23
6,779
18
Methyl alcohol
N,N–dimethylformamide Styrene
161,273
13
Butyl alcohol
6,381
14
1,3–butadiene
1,844
12
192
12
1,003
11
Methyl cellosolve Propylene oxide
② Compliance with Dioxin Emission Control Regulations DIC currently has three incinerators at three plants that qualify as “specified facilities” under the Law Concerning Special Measures Against Dioxins. One of these incinerators, which has a maximum hourly capacity of 200 kilograms, is scheduled to cease operating by December 2002, when measures relating to such “specified facilities” will be introduced. The remaining two incinerators, which also have capacities in excess of 200 kilograms per hour, comply with legal standards governing such incinerators. Accordingly, both are slated to remain in operation.
③ Reduction of Use of Ozone-Damaging Chemical Substances DIC currently uses HCFC–141b gas in some of its expandable urethane resins. HCFC–141b was added to the list of designated ozone-damaging chemical substances as the consequence of a revision of the Law Concerning the Protection of the Ozone Layer in June 1994. DIC is developing an alternative to HCFC–141b gas and intends to cease use of the substance by 2004.
10
2002 ESH Activities
4. Safty Control of Chemical Substance
1 ）Preparation and Presentation of Safety Information on Chemical Substances The recently revised Labor Safety Hygiene Law and the Poisonous and Deleterious Substances Control Law, as well the newly established Law Concerning Reporting, etc. of Release to the Environment of Specific Chemical Substances and Promoting Improvements in Their Management, call for increased efforts by manufacturers to prepare and distribute product material safety data sheets (MSDSs) for chemical substances. DIC actively advocates the preparation and distribution of MSDSs that comply with new legislation and has finished modifying its own MSDS forms. DIC also prepares MSDSs in local languages for products sold in overseas markets. In fiscal 2001, the Company prepared 5,037 MSDSs in languages other than Japanese, an increase of approximately 700 from fiscal 2000.
2 ）Internal Assessment of Chemical Substances and Production Processes In fiscal 2001, DIC conducted 420 internal assessments of chemical substances and production processes, the results of which were incorporated into measures aimed at reducing chemical substance-related risks. With the aim of reinforcing chemical substance-related risk management, DIC has established an internal Chemical Substance Control Committee. The committee is charged with reducing related risks through such measures as promoting education regarding the appropriate use of chemical substances, the reduction of the volume of chemical substances used, the improvement of production processes and the development of alternative substances.
3 ）Quality Assurance The DIC quality assurance system allows the Company to immediately suspend production of a chemical substance and take appropriate steps, such as recalling products, should there be a danger of damage to the environment or the safety or health of employees or customers. No such incidents occurred in fiscal 2001.
5. Safety during Transportation DIC has established an emergency notification system to facilitate rapid responses to emergencies occurring during transportation of chemical substances. The system involves the distribution of transportation emergency response cards (“yellow cards”), which are given to drivers of container trucks, lorries and general mixed-freight transport trucks. In fiscal 2001, yellow cards were distributed to 98% of these drivers.
6. Green Procurement In January 2002, the parent company established internal standards for Green Procurement and asked its principal suppliers to conduct voluntary assessments using prepared questionnaires. Based on the results of these evaluations, procurement from suppliers meeting these standards accounted for 89% of total procurement in fiscal 2001. DIC will continue to encourage suppliers who do not meet these standards to implement changes and intends to achieve a 100% Green Procurement rate by the end of fiscal 2005. DIC's Green Procurement rate is calculated as: Total procurement from suppliers that internal Green Procurement standards Total procurement by procurement departments
×100
Table 4 DIC’s Green Procurement Standards (Suppliers must meet standards in both columns to qualify.) Activities A supplier must either ・have earned ISO14001 certification or have a management system in place and a definite schedule for applying for ISO 14001 certification or ・conduct its operations in accordance with the principal requirements for ISO 14001.
Materials Procured A supplier must
・supply materials that contain no prohibited substances, e.g., substances prohibited under the Labor Safety Hygiene Law or Type 1 substances prohibited under the Law Concerning the Examination and Regulation of Manufacture, etc. of Chemical Substances
As well, a supplier must either
・have a program in place for reducing emissions of substances harmful to the environment or ・recycle containers or otherwise contribute to environmental preservation.
7. Soil Analysis at Former Plant Sites As part of its efforts to reorganize its domestic manufacturing network, DIC closed its Amagasaki and Warabi plants in September 2001 and March 2002, respectively. Subsequently, DIC conducted soil analyses at both sites in accordance with the Ministry of the Environment’s guidelines for measuring soil and groundwater pollution, issued in 1999.
11
Responsible Care Care Responsible DAINIPPON INK AND CHEMICALS, INCORPORATED Development of Environment-Friendly Products DIC manufactures a number of environment-friendly products. For more information, visit the following page at DIC’s Web site: http://www.dic.co.jp/products/envfprod/index.html
1. Waterborne and Solvent-Free Products ・Water-dispersing urethane resin for use in molding strong, flexible capsules
VONDIC series
・Water-soluble can coatings ・Waterborne gravure ink for flexible packaging (surface printing)
MARINE GLOSS PE
・Waterborne gravure ink for flexible packaging (reverse printing)
ECOFINE; MARINE PLUS SK; HR
・Gravure ink for shrink labels
FINE LAP WPV
・Water-based adhesives
DICDRY WS series
2. Low- and NonVOC Products ・Intermediate offset ink containing aroma-free solvent (less than 1% aromatic ingredients)
New Champion F-Gloss
・100% vegetable oil-based offset ink
Naturalith 100
Soybean oil-based sheetfed offset ink
New Champion Naturalith 100
NonVOC sheetfed offset ink
Naturalith 100 POP
・Soybean oil-based news ink
News Zett Naturalith series
・Electron beam-curable top coating for decorative paper
Beam EB300 series
・Hybrid UV-curable ink requiring no special equipment
Daicure Hy-Bryte system
・Fluorine resin for wear-resistant coatings
Fluo-Net FEM series
・Urethane/acrylic composite polymer emulsion
VONCOAT CG series
・Solvent-free waterborne urethane ionomer resin
HYDRAN HW series
・Low formaldehyde-emission phenol resin adhesive
PHENOLITE
・Low-VOC decorative boards that improve room air quality
DIC Ambiente series (Esterboard; V-Shape Board)
Daicure Hy-Bryte system
12
New Champion Naturalith 100
2002 Development of Environment-Friendly Products
3. Recycling-Related Products ・Extrusion coating resin that facilitates recycling of paper
DIC THERM RP-100
・Artificial boards made from waste plastic
DIC WOOD
・Double-sided adhesive tape for molded plastic components
Daitac #8800CH
・Film and adhesive labels made with the same materials
Daiheart S series; Ecocycle series
as food packaging trays, which therefore do not have to be removed before recycling
4. Environment Protection ・Intermediate offset ink containing aroma-free solvent (less than 1% aromatic ingredients)
New Champion F-Gloss
・Halogen-free inflammable novolac resin
PHENOLITE 7050 series
・Environment-friendly nonchlorofluorocarbon rigid polyurethane spray foam
HIPROX RP8000
・Soil control system using oxygen-free water
REVITAR
・Sheet heater for pavement, floor and roof
DAIELEC Heater
・Barium-free red monoazo pigment
SYMULER RED 3119
5. Waste Reduction ・Thick sheet molding compound (SMC) that facilitates 50% reduction of waste film
GMC series
6. Fume Reduction ・ Low-fume liquid urethane water-resistant coatings
Flatone (for flat surfaces); DIC Urethane series (primer)
7. Timber Resource Conservation Products ・Lightweight rigid polyurethane sandwich panel for truck beds
Decorative surface: PET specialty resin sheet Adhesive layer Base: Medium-density fiberboard (MDF) (EO Evolutionary Computation Framework-compatible) or composite board (FcO-compatible)
DIC Ambiente series (Esterboard)
DIC U-Panel series
Decorative surface: urethane resin sheet Adhesive layer Base: MDF (EO Evolutionary Computation Framework-compatible) or composite board (FcO-compatible)
DIC Ambiente series (V-Shape Board)
13
Responsible Care Care Responsible DAINIPPON INK AND CHEMICALS, INCORPORATED ESH in Research and Development and New Businesses 1. R&D 1 ）Safety Training for Employees In line with its Safety in Technology and Research Policy, DIC provides general safety and workplace safety training to employees.
2 ）Development of Environment-Friendly Products DIC is also actively committed to the development of environment-friendly products. Achievements to date include emulsions that uses water as a diluent, products with reduced solvent content and decorative boards for residential interiors containing almost no substances identified as causing increased VOC concentrations in rooms. In fiscal 2001, DIC launched a new intermediate offset ink containing aroma-free solvent, while Naturalith 100—a 100% vegetable oil-based offset ink containing no VOCs developed in a cooperative project with electric and information equipment manufacturers—was awarded the JCIA’s Technology Prize. Principal environment-friendly products manufactured by DIC are listed on page 12–13 of this report.
2. New Businesses Prior to preparing its capital investment plan for fiscal 2001, DIC conducted an advance safety assessment aimed at enhancing the safety and reliability of management systems and reducing the margin for human error. Plants were subjected to process safety management (PSM) procedures, while new R&D centers were designed to be energy-efficient and equipped with organic solvent and exhaust gas processing and rainwater recycling facilities.
ESH in International Operations DIC provides extensive Responsible Care training to managers assigned to overseas affiliates prior to sending them abroad. English-language versions of DIC’s Safety Procedures for Static Electricity and Testing and Principles of Safe Conduct: Procedures and Attitudes for a Safe Workplace have been distributed to affiliates in Southeast Asia. The DIC Central Research Laboratories provide safety information on chemical substances to the Company’s R&D facilities overseas, thereby ensuring maintenance of the highest ESH standards.
ESH in International Transactions In addition to adhering to the rules outlined in its Safety Management for International Trade Manual, DIC has prepared a checklist for employees traveling overseas on business to prevent the illegal export of products, regulated substances and technologies. DIC also keeps abreast of information on trafficking in prohibited substances and has established an internal mechanism to ensure adherence with international regulations.
14
2002 Interaction with the Local Community Copies of DIC’s Responsible Care Report 2001 were distributed to plants and the DIC Central Research Laboratories, together with the Principle and Policy for the Environment, Safety and Health, for internal use and for handing out to visitors to the Company. The report can also be viewed by visiting DIC’s Web site at http://www.dic.co.jp/eng/rc/index.html. During the period, DIC’s Chiba Plant participated in the Japan Responsible Care Council’s fiscal 2001 Responsible Care Conference as a representative of Chiba Prefecture. DIC invited local residents to visit its plants throughout Japan in an effort to promote effective communication. As well, DIC employees volunteered their time in the community in a variety of capacities, including serving as automobile safety and sports instructors and participating in local clean-up efforts.
DIC Plants / R&D Center
Ishikari Plant
Gunma Plant
Tatebayashi Plant
Saitama Plant
Kashima Plant
Tokyo Plant
Chiba Plant
DIC Central Research Laboratories
Mikawa Plant
Komaki Plant
Yokkaichi Plant
Shiga Plant
Ishikari Plant Mikawa Plant Komaki Plant Shiga Plant Suita Plant
Suita Plant
Gunma Plant Tatebayashi Plant Saitama Plant DIC Central Research Laboratories
Sakai Plant
Fukuoka Plant Sakai Plant
Kashima Plant Tokyo Plant Chiba Plant Yokkaichi Plant
Fukuoka Plant
15
Responsible Care Care Responsible DAINIPPON INK AND CHEMICALS, INCORPORATED Introducing the Mikawa Plant Outline The Mikawa Plant is located at the mouth of the Tedori River, which flows from Mt. Hakusan in the Kirigamine range, and close to the Komatsu coast, which is considered one of Japan’s most beautiful coastlines. The plant, which commenced operations in 1959, represents Ishikawa Prefecture’s first successful bid for a manufacturing facility and remains the only synthetic resin plant on the Japan Sea coast. The plant currently has a total floor space of approximately 140,000 square meters and employs 210 people.
Responsible Care Activities at the Mikawa Plant
Takeo Nakamura
Hiroyuki Furukawa
Yasuzo Nakatani
General Manager, Mikawa Plant
General Manager,
Manager in charge of environment and safety management,
Environment, Safety and Quality Control Department,
Mikawa Plant
1 ) Labor Accident Prevention
Mikawa Plant
Efforts to prevent labor accidents at the Mikawa Plant center on stringent observation of three key principles of prevention; employee education involving examination of past emergency situations and their causes; strict checks by general managers and managers; and participation in a DIC Group safety committee. In May 2002, the plant marked 29 consecutive labor accident-free years and 8.1 labor accident-free hours. The Mikawa Plant has also won the Minister of Health, Labour and Welfare’s First Prize (Safety) twice, a national record. 2 ) Industrial Waste Reduction The Mikawa Plant’s industrial waste reduction program focuses on taking steps to minimize output and recycling waste using subcontractors. While the plant has made notable progress on many fronts, measures to reduce the amount of surplus contaminated sludge from wastewater processing facilities disposed of as landfill have been less successful than anticipated. Accordingly, the plant has begun recycling surplus contaminated sludge into fertilizer and fuel and is working to lower output. Through these and other efforts, Mikawa Plant aims to achieve zero emissions by fiscal 2010. The plant’s recycling rate in fiscal 2001 was 65.1%. 3 ) Lower Energy Consumption With the closure of its formalin facility, which played a key role in heat recovery, the Mikawa Plant established an Energy Efficiency and Waste Management Committee and has switched its emphasis to installing energy-efficient facilities and implementing innovative ideas for lowering energy consumption. The plant is also stepping up patrols and otherwise enhancing its monitoring of consumption. In fiscal 2003, the plant plans to introduce a cogeneration system. 4 ) Safety Control of Chemical Substances/Employee Training Because it handles self-reactive substances with low boiling and ignition points, the Mikawa Plant conducts on-site employee training using MSDSs as materials and implements measures aimed at improving the working environment for its employees. These include modifying procedures to, for example, eliminate the causes of accidents. In fiscal 2001, the plant’s collection rate for MSDSs was 91% for raw materials and 100% for finished products. 5 ) Compliance with ISO 14001 The Mikawa Plant obtained ISO 14001 certification in fiscal 1997, together with the Kansai Polymer Plant (Sakai) and the Amagasaki Plant, and in August 2000 completed its first inspection for renewal. In line with DIC’s Principle and Policy for the Environment, Safety and Health, the Mikawa Plant is committed to safety, a low environmental burden, the reuse of resources and the reduction of energy consumption through the full life cycle of chemical products, from development to disposal. The plant has established an internal auditing system to ensure this commitment is met. 6 ) Interaction with the Community The Mikawa Plant is close to the Hokuriku Line’s Komatsu Station, a center of community life. Accordingly, maintaining good relations with local residents is essential. To this end, the plant has installed state-of-the-art exhaust emission reduction equipment and incinerators. As well, the plant has contracted 12 households in the immediate vicinity to monitor air quality and set up a quick-response system to ensure complaints about air quality are addressed promptly and effectively. A plant representative visits these 12 households monthly to gather information. Mikawa Plant employees participate actively in a variety of community activities, including clean-up efforts, the local traffic safety council, fire prevention and safety committees and the town’s chamber of commerce.
16
Overview of Mikawa plant
Planting fir tree seedlings as part of a local greening program
2002 History of DIC’s Environment and Safety Program 1973
1974
Environment and Safety Response Department established under direct supervision of DIC’s President
Year
Recipient
Award
1973
Amagasaki Plant
Effort Prize (Minister of Labor)
Internal safety audit conducted
1974
Warabi Plant
Effort Prize (Minister of Labor)
1976
Warabi Plant
First Prize (Hygiene) (Minister of Labor)
1978
Mikawa Plant
Progress Prize (Minister of Labor)
Environment and Safety Management Regulations and Working Regulations for Interim Countermeasures Department established Inspection of environment and safety precautions at major plants undertaken
1977
Large-scale waste incinerator installed at Chiba Plant
1979
Procedures for Using New Chemicals established Questionnaire on Characteristics of Chemicals established
1982
Guidelines for Training Inexperienced Workers ( New Employees) established
1983
Professional sanitary guidance qualifications made mandatory for all managementlevel personnel
1984 1985
Environment and Safety Awards Received by DIC
Sakai Plant
Progress Prize (Minister of Labor)
1979
Hokkaido Plant
Effort Prize (Minister of Labor)
Mikawa Plant
Effort Prize (Minister of Labor)
1981
Tokyo Plant
Effort Prize (Minister of Labor)
1982
Mikawa Plant
First Prize (Safety) (Minister of Labor)
1984
First Prize (Hygiene) (Minister of Labor)
Mikawa Plant
First Prize (Hygiene) (Minister of Labor)
Inspection of environment and safety precautions at branch offices, subbranches and sales offices launched
1987
Sakai Plant
First Prize (Hygiene) (Minister of Labor)
1989
Amagasaki Plant
First Prize (Hygiene) (Minister of Labor)
5 S Procedures and Attitudes for a Safe Workplace and Examples of Emergency Situations published
1991
Sakai Plant
Progress Prize (Minister of Labor)
1992
Chiba Plant
Effort Prize (Minister of Labor)
Sakai Plant
Top Hazardous Substance Operation Commendation
Chiba Plant
Top Plant for High-Pressure Gas Safety Commendation
Mikawa Plant
Top Hazardous Substance Operation Commendation
1987
Campaign to identify potential accidents launched
1988
Environment and Safety Guidelines for the R&D Department published Environment and Safety Management Regulations revised to include section on global environmental preservation
(Commissioner, Fire Defense Agency) 1993
(Minister of International Trade and Industry) (Commissioner, Fire Defense Agency) Safety Effort Award, JCIA 1994
Environment and Safety Philosophy formulated Accident-free year achieved for entire Company
Voluntary Long-Term Environment and Safety Plan formulated
Top Hazardous Substance Operation Commendation
Sakai Plant
First Prize (Safety) (Minister of Labor)
Warabi Plant
Top Hazardous Substance Operation Commendation
Saitama Plant
Progress Prize (Minister of Labor)
Nagoya Plant
Effort Prize (Minister of Labor)
Chemical substance safety information officer appointed in each division
Amagasaki Plant
Top Hazardous Substance Operation Commendation
Various commemorative events held to mark 20th year of DIC’s environment and safety program
Nagoya Plant
Top Hazardous Substance Operation Commendation
Public pledge to uphold principles of Responsible Care announced by DIC in its role as a founding member of Japan's Responsible Care movement
Fukuoka Plant
Special Commendation (JCIA)
Mikawa Plant
Top Plant for High-Pressure Gas Safety Commendation
Procedures and route for reporting and communicating instructions in the event of an accident established for domestic and overseas affiliates
Tokyo Plant
Top Hazardous Substance Operation Commendation
The Aftermath of the Great Hanshin-Awaji Earthquake published, chronicling conditions following the disaster
Tokyo Plant
Safety Award (JCIA)
Fukuoka Plant
Top Hazardous Substance Operation Commendation
Ishikari Plant
Top Hazardous Substance Operation Commendation
Suita Plant
Top Hazardous Substance Operation Commendation
Guidelines for Crisis Management in the Event of an Accident established
Responsible Care audit system established 1996
Effort Prize (Minister of Labor)
Chiba Plant
(Commissioner, Fire Defense Agency) 1996
Guidelines for Preventing Accidents Caused by Static established
1995
Suita Plant
(Commissioner, Fire Defense Agency) 1995
Guidelines for Preparing MSDSs established 1993
First Prize (Hygiene) (Minister of Labor)
Hokkaido Plant
Guidelines for Implementing Management Directives on Key Environment and Safety Issues published
1992
Effort Prize (Minister of Labor)
Tokyo Plant
1986
Campaign to reinforce 5 S Procedures and Attitudes for a Safe Workplace launched following several accidents
1990
Sakai Plant
(Commissioner, Fire Defense Agency) (Commissioner, Fire Defense Agency) 1997
(Minister of International Trade and Industry) (Commissioner, Fire Defense Agency) 1998
(Commissioner, Fire Defense Agency)
Guidelines for Selling Chemical Products established
(Commissioner, Fire Defense Agency)
Safety and Quality Control Supervisor appointed at sales office Responsible Care Report 1996, DIC’s first Responsible Care report, published
1999
(Commissioner, Fire Defense Agency)
ISO 14001 certification obtained by Kashima Plant from Japan Quality Assurance Association
Kansai Polymer Plant Sakai Plant
Safety Effort Award (JCIA)
1997
Sakai, Amagasaki, Mikawa, Chiba, Tokyo, Saitama, Yokkaichi, Gunma and Komaki plants obtain ISO 14001 certification
Nagoya Plant
Progress Prize (Minister of Labor)
1998
PSM Guidelines published First edition of Examples of Accidents and third editions of Examples of Emergency Situations and Procedures and Attitudes for a Safe Workplace published Suita, Warabi and Nagoya plants obtain ISO 14001 certification
1999
PRTR chemical emission levels announced
2000 Registration and monitoring of chemical emissions are modified in compliance with new PRTR system
2000 2001
Mikawa Plant
Safety Award (JCIA)
Mikawa Plant
First Prize (Safety) (Minister of Health, Labour and Welfare)
DIC
Chairman’s Award (Japan Industrial Safety and Health Association)
Saitama Plant
Top Hazardous Substance Operation Commendation (Commissioner, Fire Defense Agency) First Prize (Safety) (Minister of Health, Labour and Welfare)
Environment-related costs and investments published in line with standards for environmental accounting issued by Japan’s Environment Agency 2001
Emission volumes for “priority” PRTR chemicals, i.e., those for which emissions exceed 10 tons, published
17
Printed on nonwood paper (50% bagasse/50% recycled paper fibers) using DIC’s Naturalith 100 vegetable oil-based offset ink
“Responsible Care” refers to activities pledged and carried out by companies that manufacture and/or handle chemical substances with the aim of protecting the environment, safety and health and to the implementation and continual revision of measures to accomplish this aim throughout the full life cycle of chemical products, from development and production through distribution and use to final consumption and disposal.
Enviroment, Safety & Quality Management Department DAINIPPON INK AND CHEMICALS, INCORPORATED DIC Building, 7-20, Nihonbashi 3-chome, Chuo-ku, Tokyo 103-8233, Japan PHONE: +81(3)5203-7753 FAX: +81(3)3278-0253 URL: http://www.dic.co.jp/eng/rc/index.html
