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In December 2009, the Yodogawa Plant was certified as a Green Heart Factory. This was the result of all employees making that all important extra effort and working together to systematically reduce environmental impact while strengthening relations with society.
Green Heart Factory:
The system was introduced in fiscal 2006 to certify factories with outstanding environmental performance as Green Heart Factories. Plants that score at least 85 points out of 100 on seven criteria including reduction of environmental impact and relations with the local community are designated as Green Heart Factories.
|Address||1-1, Nishi-Hitotsuya, Settsu, Osaka 566-8585, Japan|
|Site area||Approx. 413,000m2|
|Employees||2,262 (As of March, 2018)|
|Main products||Fluorochemical products, Air conditioning/refrigeration equipment, oil hydraulic products, precision defense equipment, other|
|ISO 14001 certified||1997|
|Latest ISO 14001 update||March 24, 2016|
|Bird's-eye view of Yodogawa Plant|
In 1998, the Yodogawa Plant installed equipment for the destruction of recovered fluorocarbons so that it could carry out this activity on site.
Besides conducting thorough recovery and destruction of fluorocarbons generated during Daikin manufacturing, the Yodogawa Plant properly destroys the fluorocarbons that the Service Department recovers from customers and other outside entities.
Destruction facilities for recovered fluorocarbon
After the fluorocarbons have been completely broken down at a combustion destruction temperature of 1,250°C, they are rendered harmless.
The Yodogawa Plant has introduced cogeneration systems, which make use of the waste heat generated during power generation. The result has been a 20% reduction in CO2 emissions.
The plant has installed a waterproof, all-in-one flexible solar power generation system on the roof on a trial basis. The system uses Daikin ETFE fluoropolymer film to improve the solar panels' resistance to weathering and dirt. The system can generate up to 6 kW (enough to power two homes).
Lighting in regularly used rooms like offices and conference rooms was converted to inverter-type fluorescent fixtures, resulting in a decrease in electricity for lighting of about 30%. The plant is also gradually switching outdoor lighting to LED.
The plant's environmental activities include patrols to ensure the facility is operating in accordance with the energy saving management guideline. For example, patrol members check things like temperature settings for space heating and cooling, the energy saving modes of PCs, and the turning off of unnecessary lights. These patrols also make all employees aware of their role in saving energy.
The Technology and Innovation Center (TIC) inside the Yodogawa Plant is an advanced environmental facility aimed at achieving zero-energy buildings (ZEBs). The TIC's collection of the latest technologies includes state-of-the-art air conditioning equipment and an optimal control system for achieving both energy efficiency and a comfortable indoor environment, the efficient use of heat through equipment such as a tracking solar panel system, and ZEFFLE infrared reflective coating.
For these environmental efforts, the Technology and Innovation Center earned LEED® Platinum certification from the U.S. Green Building Council for its energy efficiency and green design. It has also earned the highest certification (S class) in CASBEE (Comprehensive Assessment System for Built Environment Efficiency), a highly recognized system in Japan for the comprehensive assessment of the environmental performance of buildings, districts, and cities. CASBEE was created by the Institute for Building Environment and Energy Conservation (IBEC).
In September 2004, the Yodogawa Plant achieved zero emissions (recycling ratio of at least 99.5%).
Unnecessary items from offices and production processes are separated for recycling. The recycling bins are see-through to ensure materials go in their proper place.
Posters with photos of waste items to be separated are placed at separation stations to ensure materials get recycled properly.
Unnecessary items are separated and recycled as, for example, solid fuel, boards, and cement.
The plant works to reduce the amount of VOCs, such as the solvents used in the fluoropolymer manufacturing process, released into the atmosphere by recovering at least 70% of them using activated charcoal.
Daikin has stipulated an in-house standard value that is 25% stricter than legal limits for plant wastewater. The plant works daily to ensure measurements for items such as fluorine and pH do not exceed in-house standard values.
The plant carries out thorough control of the quality of the wastewater discharged by using activated charcoal and other methods to remove at least 99% of the emulsifiers and other substances used in the fluoropolymer manufacturing process.
Thirteen employees from the Yodogawa Plant joined the special firefighting team of Settsu City, which is the first of its kind in Japan. These employees have a registered pump truck and make up the Daikin team. Since January 2010, the Daikin team responds to requests for assistance in case of a fire nearby and at the site offers assistance under the guidance of the Settsu City Fire Department.
In preparation for a range of disasters, such as flooding and fires from a major earthquake and tsunami, or chemical leaks, emergency materials and equipment are stored at 22 locations at the Yodogawa Plant. In case of a major disaster, there are stockpiles of water, food, and toiletries so that employees can monitor the chemical plant and ensure safety at the site around the clock.
The plant holds comprehensive disaster training three times a year with participation from the fire department and police department. The plant also takes part in disaster training sponsored by Osaka Prefecture and Settsu City.
A system was established that can confirm the safety of all people on the site including visitors approximately 20 minutes after a disaster occurs, thus ensuring that each and every person is accounted for.
Every August, local residents are invited to a Bon dance festival held on the grounds of the Yodogawa Plant. The 45th edition of the festival in 2016 was attended by 23,500 people.
The Yodogawa Plant's Yushinkan kendo training hall has been moved to a new location and is now a multi-purpose gymnasium. It is open to the public as a way for Daikin to contribute to the community.
Grade 3 students from two nearby elementary schools were given factory tours in 2010. The children listened and watched with intense curiosity and many later wrote thank-you letters to Daikin.
Division and section managers lead cleanups of local streets once a month. Participants are often encouraged by words of gratitude from passers-by.
Residents of Daikin's bachelors' dormitory join local residents in cleaning up waterways, part of the Yodogawa Plant's efforts to join in preserving the local environment.
Besides the emergency materials and equipment previously mentioned, the Yodogawa Plant has two sheds on-site containing emergency supplies for local residents to use during a disaster. At annual plant tours for the neighborhood association, Daikin shows how to use these supplies.
|Substance name||Amount emitted||Amount transported|
|Antimony and its compounds||0.0||0.0||0.0||850.0||0.1|
|1-chloro-1,1-difluoroethane (also called HCFC-142b)||11,000.0||0.0||0.0||0.0||0.0|
|Chlorodifluoromethane (also called HCFC-22)||34,000.0||0.0||0.0||0.0||0.0|
|2-Chloro-1,1,1,2-tetrafluoroethane (also called HCFC-124)||1,600.0||0.0||0.0||0.0||0.0|
|Dichloromethane (also called methylene chloride)||13,000.0||0.0||0.0||2,900.0||0.0|
|Hydrogen fluoride and its water-soluble salts||0.0||0.0||0.0||41,000.0||0.0|
|Water-soluble salts of peroxodisulfuric acid||0.0||0.0||0.0||0.1||0.0|
|Poly (oxyethylene) alkyl ether (alkyl C=12-15)||0.0||0.0||0.0||49,000.0||630.0|
|Molybdenum and its compounds||0.0||0.0||0.0||34.0||0.0|
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