2010 environmental report - lucart group · 3.2 raw materials 3.3 water ... all data shown in the...

2010 Environmental Report

a year with

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Letter from the Chairman

LUCART GROUP1.1 Mission, vision & values1.2 About us1.3 The production sites1.4 Points of environmental excellence1.5 Eco school award1.6 Natural project

06080912131415

THE MAIN ENVIRONMENTAL ASPECTS3.1 Environmental performance indicators3.2 Raw materials 3.3 Water3.4 Energy3.5 Air Emissions3.6 Waste3.7 Transportation

242627 2831 333438

IMPROVEMENT TARGETS 16

HEALTH AND SAFETY 40

PLANT DATA TABLES 44

PREFACE 04

pag. 03

Contents

0302

Lucart Group is proud to present the seventh edition of the Environmental Report, once again emphasizing the company’s determination to make the relationship between business and the environment ever more positive.

Today everyone is talking about the environment; the public, the authorities and businesses have been placing environmental protection and sustainable development amongst their priorities.

This is obviously a good thing and calls for congratulations, but our hope is that more and more people will start to walk the walk, and not just talk the talk. In terms of environmental protection, in fact, everyone should do his or her part and every single gesture is important.

Anyone who knows our history can testify to the fact that our commitment to the environment dates back to well before it became fashionable.

Over the years we have continued our commitment, receiving all of the major product and environmental certifications. But what really makes our “green philosophy” unique is the desire to utilize our experience, know-how and expertise when making truly green products, while at the same time offering top value to our consumers and clients.

Among the projects in 2010 that are concrete evidence of our commitment to protecting the planet, I am pleased about the extension of the FSC international forest certification brand to all Group production facilities. We also stood out in the second annual “Trophées Développement Durable”, organized by Carrefour International, and dedicated to sustainable development. We won first place in the “Progression” category for our commitment to the reduction of carbon dioxide emissions and to sustainable procurement management.

We have also been chosen amongst the best projects for the “Environmentally Friendly Innovation 2010”, award, promoted by Legambiente, Regione Lombardia, Fondazione Cariplo and Confindustria, for our Natural project.

It is important to note these operations not only concern the production facilities, but the whole supply chain, from raw materials to distribution. Our commitment to the environment is all-encompassing.

Massimo PasquiniLucart Group CEO

Letter from the Chairman

0504

Preface

This is the seventh edition of the Lucart Group Environmental Report.

The environmental data displayed in this document refers to all the Group sites.

Since the Fato Professional spa plant, situated in Torre di Mosto (Venice - Italy), is not equipped with continuous machines for the production of paper or with waste purification plants, the relative consumptions (electricity, water and fibrous raw material) and emissions into the atmosphere and water are not included into the tables of performance indicators of the Group, when they are proportional to the quantity of paper produced.

Fato Professional became a part of Lucart Group at the end of 2007, therefore only data from 2008 is provided.

Novatissue sas, located in Laval sur Vologne (France), became a part of Lucart Group in October 2008; therefore only data for 2009 and 2010 is provided.

All data shown in the Environmental Report is up to 31st December 2010.

LUCART GROUP

Today Lucart Group is one of the main producers in Europe of MG (mono-glazed) paper for flexible packaging, and is among the top 10 producers in Europe of tissue paper and products.

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08 09

1.1 Mission, vision & values

Lucart Group was one of the first European paper production groups to include the value of the environment in its company mission.

Mission To excel in the production of high quality paper by responding to market and environmental needs.

Vision We want to be a partner and point of reference for all our customers in the various markets we operate in, standing out for quality, professionalism and the reliability of our work.

Values• Professionalism. A long-term strategy must be based on professionalism, competence, reliability and fairness.• Quality. Excellence in the quality of our products and services, through a continuous research in innovation, is the best way to guarantee a high level of customer satisfaction.• Responsibility. A modern entrepreneurial business must follow a responsible development model that guarantees the respect of rights and regulations, personnel training and enhancement, and the safety and well-being of the working environment.• Sustainability. Sustainability is a constant commitment to reducing environmental impact throughout the whole production process and the promotion of a more rational use of virgin as well as recycled fibre pulp according to the end use of the finished product.• Profitability. Value must be created for customers, employees and shareholders to guarantee continuity and growth of our Group.

Business Area Market DescriptionBusiness to Business European leader in the

industry of mono-glazed, low paper thickness, and partner for major European converting companies.

Paper used by other converting companies for the production of bags, gift paper, paper laminated with polyethylene or aluminium, table-covers, other flexible packaging in general or tissue paper for sanitary use.

Professional Market leader in Italy and gaining market share in Europe: 5th European main producer.

Tissue paper products, such as toilet paper, hand towels or napkins, for “away from home” consumption, such as for restaurants, companies, cleaning companies etc.

Consumer Market leader in Italy for ecological tissue, and partner for European mass distribution for both pure cellulose as well as recycled paper private label products.

Tissue paper products, such as toilet paper, household paper, napkins and handkerchiefs, used “at home”.

The business areas in which the Lucart Group operates are:

% influence of each business area on total turnover

Business to Business20%

Professional34%

Consumer46%

Over 50 years of experience have enabled us to develop the know-how, experience and technology to create quality products which are able to meet our customers’ needs in the best way possible.Our production plants at the various Group sites allow us to create a wide range of products, with control over all phases of the production process, from choosing the raw materials through to determining the characteristics of the finished product.

1.2 About us

10

Company Plant / Premises Activity Business AreaCartiera Lucchese spa(Italy)

Porcari • Production of MG paper forflexible packaging

• Production of tissue paper

Business to Business

Diecimo • Production of tissue paper

• Converting of tissue paper intofinished products

ProfessionalConsumer

Lucart France sas(France)

Troyes • Production of tissue paper


Consumer

Novatissue sas(France)

Laval sur Vologne • Production of tissue paper


Professional

Lucart Ibérica slu(Spain)

Barcelona • Commercial activity for Spanishand Portuguese customers

Professional

Fato Professional spa(Italy)

Torre di Mosto • Converting of tissue and MGpaper into finished products

ProfessionalConsumer

Companies/Plants locations

Lucart Group’s paper production capacity exceeds 280,000 tonnes/year, with over 9 continuous machines and 56 converting lines.The consolidated turnover is 350 million Euros, with approximately 1,100 employees. The total surface area of the production sites is over 850,000 m2.

Group Structure

Cartiera Lucchese spa

100% Lucart

France sas

100% Novatissue

sas

100% Fato

Professional srl

100% Lucart

Ibérica slu

Company activities CONSUMER

Our main brands

PROFESSIONAL

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1.3 The production sites

Lucart Group has five production sites; 3 in Italy and 2 in France

The Porcari plant, situated about 10 kilometres outside Lucca, produces thin MG paper for flexible packaging and tissue paper for hygienic/sanitary use from both pure pulp and recycled paper. Special converting lines allow the MG paper to be cut to size or waxed paper to be produced.In Diecimo (Borgo a Mozzano), about 20 km north of Lucca, tissue paper is produced, using both pure pulp and recycled paper as raw materials. These types of paper are also transformed into finished products destined for end consumers.The Porcari and Diecimo sites are equipped with cogeneration plants for producing electrical energy and steam powered by methane gas, two “regeneration” plants for recycled paper, two modern plants to recover plastic from waste paper and autonomous wastewater treatment plants.

The Torre di Mosto site produces tissue and monoglazed finished goods for Ho.Re.Ca and consumer market.

The Troyes site, situated about 200 km south-east of Paris, is completely dedicated to producing and converting tissue paper, though using only pure cellulose (pulp) as raw material. In Laval sur Vologne, situated in the Lorraine region, tissue paper is produced, using both virgin and recycled fibre as raw materials. These types of paper are also converted into finished products for customers and final consumers.

Site Total surface

(m2)

Covered surface

area(m2)

N° employees

ending 31/12/10

Continuous machines

Paper Production

capacity(t/year)

Converting lines ending

30/04/11

Porcari (Lucca - Italy)

113,830 44,150 221 3 100,000 5

Diecimo (Lucca - Italy)

243,180 92,233 377 3 100,000 21

Torre di Mosto (Venice - Italy)

29,541 8,000 67 0 0 15

Troyes (France)

276,084 50,710 186 1 32,000 6

Laval sur Vologne (France)

187,471 44,000 248 2 50,000 9

GROUP TOTAL 850,106 239,093 1,096 9 282,000 56

Our continued commitment to developing products able to meet the needs of both customers and the environment increasingly well has allowed Lucart Group to reach numerous important objectives:

• First Italian company to have developed a technique for deinking pulp used to produce tissue paper and thin MG paper for flexible packaging.

• One of the first paper mills to believe in systems for self-generation of electrical energy and steam by means of cogeneration power plants powered by methane gas.

• First Italian company to obtain the Eco-label environmental certification for products issued by the European Union.

• One of the first in Europe to obtain the UNI EN ISO 9001 quality management system certification and the UNI EN ISO 14001 environmental management system certification for both tissue and MG paper.

• One of the first European integrated sites (Diecimo site) for the production of tissue (paper mill and converting in the same site) to have obtained the EMAS environmental registration.

• One of the first Italian paper mills to obtain FSC® (logo licence number: FSC-C100456) and PEFC certification (logo licence number: PEFC/18-32-05), related to the use of virgin fibres originating from forests and managed with ethical, social and environmental criteria.

• First company in the world to use MaterBi as biodegradable wrapping for tissue paper packaging.

• Once of the first European paper mills to publish an annual Environmental Report which describes and summarises the policies, programs, objectives and concrete action taken regarding the environment.

• First company in the world to launch a biologically-active toilet paper onto the market, able to reduce blockages in plumbing pipes and septic tanks.

1.4 Points of environmental excellence

1514

The ecological commitment Lucart Group pursues at a strategic level is also confirmed by communication initiatives with ethical and social background. “Grazie Lucart”, a line of recycled paper products that for the fourth time promoted an eco-pedagogical project aimed at stimulating and increasing the sensitivity of the younger generation on issues related to nature conservation and environmental education topics. Teachers and students of the classes involved in the project (primary and secondary schools all over Italy) took part in the competition by presenting a document that developed issues related to environmental protection and use of recycled paper.The big news of 2010 was the creation of a recreational-learning course with the aim of stimulating discussion and reflection on the 3 “Rs” (Recycle, Reduce, Reuse) in class and at home, teaching kids “good environmental education” and providing them with basic rules for coexistence and for developing an ecological consciousness. The course was divided up into three macro-areas (one for each “R”), had over 50 educational cards.

1.5 Eco school award

Educational cards

Stampa l’elenco dei suggerimenti che trovi qui sotto e leggilo insieme alla tua famiglia, scoprirete alcune semplici regole per ridurre gli sprechi a casa.

��a�Scuola

��a�Casa

Accendi la luce in classe solo quando necessario

Riutilizza la carta stampata su un solo lato per i tuoi appunti prima

di cestinarla

Non gettare per strada carta, plastica, gomme

da masticare, ecc.

Chiudi il rubinetto quando ti insaponile mani

Fai la raccolta differenziata

dei rifiuti

Riporre gli indumenti smessinei contenitori delle associazioni

di volontariato

In giardino, ridurre al minimo i concimi chimici, i diserbanti e

gli antiparassitari

Spegnere gli apparecchi elettrici ed elettronici

quando non li si usa

Non utilizzare il riscaldamento oltre i 20-22°

Usare lavatrice e lavastoviglie solo

a pieno carico e di sera

Dosare il detersivo in base allo sporco e alla

durezza dell’acqua

Se puoi, non usare

l’ascensore al posto delle

scale

Organizzare contenitori specifici perfare la raccolta differenziata

Scegliere prodotti naturali per l’igiene della persona e della casa

Abbasso�gli�Sprechi

RIDUCO 1

- w

ww

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it/

scu

ola

-

PROPONI�TU

PROPONI�TU

Materiale�necessario3 tubi di carta igienica vuoti, nastro adesivo, forbici, un pezzo di corda e pennarelli.

Come�si�fa

1��Con una striscia di nastro adesivo unisci tra loro due tubi di carta igienica della stessa altezza.

2��Taglia su un’estremità il terzo tubo lungo tutta l’altezza, in modo da aprirlo. Lasciandolo ricurvo, infila questo terzo pezzo di cartoncino al di sotto dei due tubi precedentemente uniti e fermalo con nastro adesivo.

3��Con le forbici pratica due fori all’estremità delle ‘lenti’ e infilaci il pezzo di corda, per poter mettere il binocolo al collo.

4��Adesso devi solo dipingere il tuo binocolo con i pennarelli.

Binocolo

RIUSO 2

- w

ww

.gra

zie.

it/

scu

ola

-

ForestaTaglio degli

alberi

DiscaricaScarto dellacarta usata

CittàUso della

carta

CartieraProduzionedella carta

DiscaricaMinore scarto di carta usata

ForestaMinore prelievo

di legno

CartieraProduzionedella carta

CittàUso della carta

Carta riciclata

Carta recuperata

Carta differenziata

Carta nuova

Un suggerimento importante

La carta riciclata dovrebbe essere scelta in particolare per quei prodotti che non è possibile riciclare una volta

usati, come nel caso dei prodotti us a e getta pe r

pulire la casa o soffiarsi il naso (fazzoletti, panni di carta…).

Normalmente, per fabbricare la carta è necessario tagliare

alberi. Dopo la sua utilizzazione, la carta viene portata in

discarica.Tuttavia, anzichè buttarla via, una parte

consistente può essere riciclata. In questo modo, si riduce il taglio di alberi e la quantità di carta scartata.

Normalmente, per fabbricare carta è necessario tagliare alberi. Ma ormai sappiamo che è anche possibile riciclare quella già fabbricata e utilizzata. Come?

Il ciclo del riciclo

La principale materia prima per la fabbricazione della carta è uno dei più importanti componenti del legno degli alberi: la cellulosa.

Le fibre di cellulosa possono essere sottoposte a ripetuti utilizzi, cioè, un foglio di carta, una volta usato, può essere riciclato per produrre nuova carta, risparmiando la vita di nuovi alberi.

Inoltre, poiché non tutti i prodotti di carta possono essere riciclati, come per esempio quelli usa e getta (come la carta casa, la carta igienica, i tovaglioli ed i fazzoletti in carta) è una scelta ecologica utilizzare quelli prodotti con carta riciclata, evitando così di sprecare fibre di cellulosa provenienti direttamente dagli alberi per realizzare della carta che comunque non sarà mai più recuperabile.

Perche devo scegliere la carta riciclata

Riciclo

RICICLO 2.3

Lucart Group with Natural project started its own eco-revolution in 2010, with the launch of a new line of eco-friendly products made from recycled cellulose fibres present in Tetra Pak containers. The innovative treatment process perfected in the Lucart plants which does not require the use of substances harmful to man and the environment, has achieved a true eco-friendly paper product with an exceptional performance. The quality of the cellulose fibres contained in Tetra Pak containers can be compared to that of virgin pulp, and can therefore give the finished product excellent durability and absorbency, as well as a light brown colour comparable to the natural colour of wood.It should also be pointed out that products of Natural line don’t cut down trees and recycle a material that would otherwise be lost: the technology developed by Lucart Group enables the recycling of plastic and aluminum parts present in Tetra Pak containers for other manufacturing activities (each container on average is made of 74% cardboard, 22% polyethylene and 4% aluminum).All Natural products are EU Eco-Label certified and they respect the strict environmental protection criteria common to all European Union countries. Eco Natural Lucart product, thanks to its innovative spirit, has also earned an award for one of the best projects presented in the “Eco-friendly Innovation Award 2010” sponsored by Legambiente (see chap. 2, par. Certifications and merits).

1.6 Natural project

IMPROVEMENT TARGETS

The objective of every Environmental Management System must be the continuous improvement in performance

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Certifications and records

In 2010, Cartiera Lucchese spa was awarded as the winner of the second annual Trophées Développement Durable organized by Carrefour International and dedicated to the theme of Sustainable Development. The jury chose from a group of 2200 suppliers of Carrefour Group, and placed Lucart Group in first place in the “Progression” category, thanks to, above all, the company’s commitment to the reduction of CO2 emissions and the management of sustainable procurement. This important recognition was welcomed by the Lucart Group management, who, along with the other participants, prepared a detailed and complete self-assessment kit and submitted to an audit performed by third parties, who were in charge of verifying whether the documents related to the award were filled out correctly.

The Trophées Développement Durable award was part of a long-term project sponsored by Carrefour International, a company that aims to bring together all of the group’s suppliers for cause of sustainable development and, in so doing, raise public awareness about the issue.

The Lucart Group also obtained recognition by participating in the “Premio all’Innovazione Amica dell’ambiente 2010”, sponsored by Legambiente, Regione Lombardia, Fondazione Cariplo and Confindustria. Eco Natural Lucart, thanks to its innovative spirit, earned a plaque for being among the best projects.This prestigious Legambiente prize is a nod to national businesses that are focused on innovation in the environmental field. It is awarded as recognition for product innovation, processes, services, systems, technology and management, completed or in an advanced state of completion. These businesses have shown that they contribute to significant improvements geared toward environmental sustainability and stand out for their originality and potential for development, including development related to the surrounding areas.

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Certificated cellulose usage

Certified cellulose is produced by companies that adopt sustainable forest management certification systems that are in accordance with internationally recognized formats.The Lucart Group has always followed a careful purchasing policy, giving priority to raw materials with low environmental impact which come from chains with certified chains of custody.

During 2010, the use of pure pulp originating from forests managed in an environmentally-sustainable way was again increased. At the end of the year, certified cellulose was over 92% of the total amount of purchased cellulose virgin fibres.Since 2009 the PEFC forest certification (logo licence number: PEFC/18-32-05) was extended to all Lucart Group sites.All Strong Lucart and Velo Pure Pulp products from the Lucart Professional range, as well as all Smile Lucart products in consumer range products are PEFC-certified.

Also, in 2010, forest certification according to the FSC®-Forest Stewardship Council- (N° logo licensing: C100456-FSC) was extended to all Lucart Group plants. It is an international non-governmental, non-profit agency that aims to ensure good forest management and establish standards for the traceability of forest products (chain of custody - CoC) through the use of a registered international trademark.

Sales of EU Eco-label certified products

Cartiera Lucchese was the first Italian company to obtain EU Eco-Label certification. All the products with this logo respect strict environmental protection criteria that are common to all countries in the European Union.

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Waste management

In order to reduce the environmental impact of waste, in 2010 all production facilities of the Group continued to raise awareness and implement systems and procedures for the collection of waste, with a significant reduction in trash disposal and assisting in recovery. The total amount of waste produced derives mainly from recycled paper or scrap pulper, with a predominance of paper mill sludge (see section 3.6).

2006 2007 2008 2009 2010

Group Total 0.41 0.32 0.31 0.39 0.35

Total waste produced per tonne of paper sold (t/t x 1000)

Logistics

Our products are very bulky and moving them therefore requires an extensive use of transportation.In order to reduce the environmental impact of this activity, in addition to using the railway feeder lines inside the Diecimo and Troyes sites where possible, and compatible with customer requirements, we also try to favour packaging and palletising which enable us to achieve the highest levels of logistic optimisation. The number of vehicles used is nevertheless heavily influenced by the type of finished products sold.During 2010 there was a reduction in the number of transports, partly due to the optimization of cargo travels through a full load, new packaging solutions for products and production of “compact products”.

2006 2007 2008 2009 2010

Group Total 182.1 189.1 189.2 186.6 184.7

Total number of incoming/outgoing vehicles (trucks and wagons) in relation to tonnes of paper sold (n/t x 1000)

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Packaging

Throughout the year 2010, we continued to seek solutions which enable us to reduce the quantity of packaging material used when packaging and shipping our products.Our continuous commitment is aimed at:

• seeking out alternative materials with a reduced environmental impact or specific weight;• seeking technical and production-related solutions which enable a reduction in materials used;• the progressive reduction of thicknesses/grams per square metre of the material normally used.

The value of the ratio between the total amount of subsidiary materials used and the total quantity of paper sold is obviously heavily influenced by the marketing mix of all articles.

2006 2007 2008 2009 2010

Group Total 57.60 70.38 79.38 57.49 55.21

Total amount of packaging and other auxiliary materials used per tonne of paper sold (t/tx1000)

Water

The process of paper production requires large amounts of water. Over the years our goal has been to optimize the water that flows through the various sites, increasing the amount of recyclables in the manufacturing process.During Hydrica 2011, the biennial exhibition dedicated to water, the Lucart Group presented all activities that is has undertaken through time as well as the 2011 targets for the reduction of water consumption during production.The Diecimo, Porcari and Laval sur Vologne’ plants have a recovery system for the purification of waste water to make it suitable to be reutilized specifically for the paper mill, replacing surface water or groundwater. The reuse benefits of this water were immediate: a reduction of the extraction of natural resources, energy and water resources renewal, consistency and reliability of the resource (thanks to the purified water produced on an ongoing basis), and a reduction in the waste of resources.To reduce water consumption over the years systems to change the flow of water inside the plants have also been installed.

2322

Communications

Management of finished products

The main tool for environmental communication on a Group level is the Environmental Report, and this is its seventh edition. Nevertheless, regarding environmental communication, the tools used to promote the Group’s products and projects are no less important. These are: internet sites, promotional/advertising initiatives, product packaging, newsletters, folders and brochures.

Lucart Group’s commitment on this front has been aimed at reducing the environmental impact of its products throughout their life cycle for quite a while now. Examples of this are:

• the continuous promotion of a rational use of virgin and recycled fibres, based on the intended use of the finished product;

• the constant commitment to reducing the amount of packaging used, through both eliminating over-packaging and reducing the specific weight of the individual packs;

• the promotion of “compact” tissue products which are optimal in a logistics sense and consequently in an environmental sense as well;

• the development of product distribution systems (dispensers) able to reduce consumption and waste, such as the innovative and exclusive Hygenius brand line.

Among the 2011 objectives of the Italian plant Diecimo, there is also the installation of another bypass to recover the clarified water, which saves chemicals and energy, and the subsequent step towards closing the water cycle.At the French plant in Laval sur Vologne, the Tetra Pak line treatment project led to the study and creation of specially designed operations, including a platform for bale storage with a water recovery system and its subsequent treatment. And in 2010, in the same facility, new filters were installed to retain hydrocarbons contained in the rainwater.

2006 2007 2008 2009 2010

Group Total (excluding Fato Professional)

13.0 12.6 11.7 12.1 12.2

Total amount of water consumed per tonne of paper produced (m3/t)

Energy savings

Most of the energy used in the paper industry is required by the paper machines. Our goal is to constantly increase the energy efficiency of our production process.In 2010 “Project Substation” was approved and will be completed in a span of 2/3 years to build a 130,000-kw power plant at the Italian Diecimo plant with the aim of reducing energy losses on transportation lines.Another goal reached in 2010 at the Diecimo plant was the extension of enzyme (modifiers of fibre that allow intercellular links to be created, and utilized in the place of high-power machinery) utilization for the PM5 and humidity-resistant paper, in addition to the purchase of high efficiency motors (class F1).

2006 2007 2008 2009 2010

Group Total (excluding Fato Professional)

1,211.7 1,153.2 1,127.3 1,132.1 1,151.1

Total amount of energy consumed per tonne of paper produced (KWh/t)

In 2010 the Diecimo facility was the subject of research on a boiler used for heating the convertingdepartment with recovery of waste heat from gas turbines and on the project for the purchasing ofelectricity from renewable sources through the installation a wind farm.There have also been structural operations on the ceilings of some production departments in order to:

• promote natural lighting,• replace the lighting in storage areas with high-efficiency LED lamps,• reduce the use of permanent light switches,• reduce energy consumption for heating and cooling needs.

At Laval sur Vologne, new inverters have been installed on electric motors (for example on the new line of Tetra Pak) in order to optimize consumption.

THE MAIN ENVIRONMENTAL ASPECTS

Through constant analysis of the most significant environmental issues we want to pursue the objective of continuous improvement of our environmental performances.

03

3.1 Environmental performance indicators 3.2 Raw materials

In order to be able to compare different data over time, Environmental Performance Indicators (EPI) have been put in place. They assess environmental efficiency, disregarding annual fluctuations in volumes, as they are related to the total quantity of paper produced by the sites.

At the Porcari, Diecimo and Laval sur Vologne plants, paper is produced both from pure cellulose as well as waste paper, while at the French Troyes plant only pure cellulose is used at the moment.The paper is composed primarily of cellulose fibres which are also the main raw materials used in our production facilities, where we use both virgin fibres, derived directly from wood, and recycled fibres, which were recovered from paper that has already been used.Since 2010 in the Diecimo plant, as well as Laval Sur Vologne since 2011, thanks to an exclusive technology we have also been regaining the cellulose fibres contained in Tetra Pak containers. The resulting cellulose has a percentage of long fibres that is greater than that of a standard mixture of cellulose. This subsequently results in an increase in resistance and absorbency of the finished product. The non-bleached cellulose fibres also give the paper a light brown hue similar to the natural colour of wood.

The environmental impact of much of our business is influenced by the choice to also use recycled paper as raw material. By simply comparing our environmental performance indicators with those of paper mills which use exclusively virgin fibres, in fact, it might seem that our index values are decidedly higher.This type of analysis, though, is incomplete and incorrect as it does not include consumption and emissions generated by the process of extracting fresh fibres from wood. Actually, the use of recycled paper for the production of paper, in addition to preventing trees from being cut down, also results in lower levels of air emissions and lower consumption of water and energy, compared with the production cycle that starts with wood. Furthermore, reusing pulp means there is no longer a need to throw away a large quantity of scrap and waste (around 25% of urban waste is made up of recyclable cellulosic materials).

Group environmental performance indicators -excluding Fato Professional-

Consumption of raw materials in tonnes (2010)

Total quantity of raw materials used in 2010

2006 2007 2008 2009 2010

Energy consumed per tonne of paper produced (KWh/t)

1,211.7 1,153.2 1,127.3 1,132.1 1,151.1

Raw material consumed per tonne of paper produced (t/t)

1.31 1.23 1.22 1.22 1.23

Water consumed per tonne of paper produced (m3/t)

13.0 12.6 11.7 12.1 12.2

Production scrap (paper sludge) and waste produced per tonne of paper produced

0.47 0.34 0.34 0.42 0.37Tonnes

Porcari 120,770

Diecimo 111,512

Troyes 31,183

Laval sur Vologne 59,941

Total 323,406

2726

Recycled paper47.9%

Pure pulp52.1%

3.3 Water

For industrial production, Lucart Group sites utilize well water that is located whithin their perimeters. Porcari also satisfies part of its water requirements by using surface water piped to the plant by a dedicated pipeline that was built by the local administration with the participation of Lucart Group. This plant has been carefully designed to safeguard the aquifer and reduce the effects of subsidence affecting the area. Water from the municipal water aqueduct is only for civilian uses.Over the years we have continually modified and optimised the flows of water at the various production facilities. The aim has been to increase the amount of recycled water during the production process, limiting the utilization of new water from the ground to just the amount that is required for replenishing.

The water consumption at all Lucart Group facilities is well below the value (25 m3/t) set by the European paper-making industry’s BAT (Best Available Technologies). Even at Diecimo and Laval sur Vologne, despite the larger amount of water consumed by the treatment of recycled paper, the value is below the Best Available Technologies (BAT) quantity.In Torre di Mosto, water is only for civilian use, therefore the water consumption of this facility has not been considered as a part of the index.In order to interpret the data correctly, it is important to remember that using recycled paper means avoiding water consumption associated with the process of extracting cellulose fibres from the wood, which can reach up to 40-50 cubic metres per tonne of pulp produced. Therefore, overall, using recycled paper saves water.

With regard to effluent water, Porcari, Diecimo and Laval sur Vologne sites are equipped with internal wastewater treatment systems, which purify the water to the standards required by the applicable legislation.As the substances contained in the paper mill wastewater are essentially of organic origin - cellulose fibres - the performance of the purifiers is assessed using the Chemical Oxygen Demand - COD - as a reference, as all other parameters have always been of relatively low importance when assessing the purifying efficiency of the plants.

2928

Water consumption - 2010

Water consumption over the years(m3/t paper produced)

Consumption (m3) m3/t paper producedPorcari 560,790 6.3

Diecimo 1,653,630 16.6

Troyes 252,489 8.2

Laval sur Vologne 752,480 16.8

Subtotal 3,219,389 12.2

Torre di Mosto 1,481 ===

Total 3,220,870 ===

2006 2007 2008 2009 2010

30 31

Value measured (mg/l) Legal Limit* (mg/l)COD 482 ≤ 1,300

Suspended solids 83 ≤ 730

Total nitrogen 4.4 ≤ 30

Total phosphorous 0.8 ≤ 50

Value measured (mg/l) Legal Limit* (mg/l)COD 53 ≤ 160

Suspended solids 10 ≤ 80




Suspended solids 94.7 ≤ 120




Suspended solids 35.3 ≤ 52.2



Quality indicators of effluent water - Porcari site - 2010

Total amount of electricity consumed* (MWh/1000)

% of on-site generated electricity compared with total energy consumed Quality indicators of effluent water - Diecimo site - 2010

Quality indicators of effluent water - Troyes site - 2010

Quality indicators of effluent water - Laval sur Vologne site - 2010

*Limits for drainage into the sewer system set by Italian legislation and by the Regolamento dell’Impianto Consortile

*Limits for drainage into surface water set by Italian legislation.

*Limits for drainage into the sewer system set by French legislation.

*Limits for drainage into surface waters set by French legislation.

3.4 Energy

Lucart Group was one of the first European paper-making companies to rely on the on-site co-generation of electricity through CHP (Combined Heat & Power) plants powered by methane gas.The on-site generated electricity is used to power the machines, while the heat resulting from the combustion of fuels is used to dry the paper on the continuous machines.

*All plants except Fato Professional

Consumed % of total

2006 2007 2008 2009 2010 2006 2007 2008 2009 2010

32 33

The cogeneration plant at Porcari is able to produce 16.5 MW of electricity and 47 t/h of steam. Diecimo, on the other hand, is able to produce 10.4 MW of electricity and 30 t/h of steam.The cogeneration plants cover the full energy requirements, both electrical and thermal, for Porcari, while in Diecimo, they cover the full requirement for heat and approximately 65-70% of the electricity requirement. For Troyes and Laval sur Vologne, the electrical energy that is utilized is completely sourced from the national grid, and the thermal energy is produced on site using methane gas as fuel.For Torre di Mosto the electricity that is utilized is completely sourced from the national grid while there is no production or consumption of thermal energy.

In addition to cogeneration, there have been other significant plant engineering operations put in place in order to save energy, such as recovery of fumes originating from the cogeneration plants when drying the paper sludge, recovery of heat when pre-heating the paper dryer system and air-conditioning the working areas.

Energy consumption – 2010

Consumption of electricity - (MWh/1000)

Porcari Diecimo Troyes Laval sur Vologne

Torre di Mosto

Methane gas

m3 43,455,354 39,446,335 6,697,120 20,440,000 71,606

Electrical energy

MWh 100,568 116,797 35,132 51,144 44

3.5 Air Emissions

Air emissions from the plants come from the cogeneration power plants, the sludge drying plants, the air extraction filters, the continuous and converting machines, and the heating systems of the paper drying hoods.Regarding the cogeneration power plants, in addition to carbon dioxide (CO2), nitrogen oxide (NOx) and carbon monoxide (CO) are also produced in limited quantities. The use of methane, also, means that the emissions contain practically no sulphur oxide. Today the cogeneration of electrical energy and heat by means of a methane gas-powered power plant is actually one of the most efficient systems, with the lowest environmental impact, that meets the elevated requirements for electrical energy and steam in paper mills.At Troyes and Laval sur Vologne, air emissions are limited to those from the gas boiler, necessary to produce steam, and from the drying hoods. At Torre di Mosto there are no significant air emissions.In 2010, with the goal of reducing energy consumption and CO2 emissions, Diecimo facility was the subject of research on a project for the construction of a wind turbine for the supply of electricity from renewable sources.

2006 2007 2008 2009 2010Porcari 1.1 1.4 1.3 1.2 1.4

Diecimo 0.5 0.9 0.9 0.9 1.0

Troyes 0.5 0.5 0.5 0.5 0.5

Laval sur Vologne == == == 0.3 0.2

2006 2007 2008 2009 2010Porcari 973.2 957.9 932.9 918.1 953.0

Diecimo 706.8 785.9 793.1 759.4 773.2

Troyes 455.3 445.6 453.3 460.1 460.8

Laval sur Vologne == == == 499.2 501.3

NOx emissions per tonne of paper produced (kg/t)

CO2 emissions per tonne of paper produced (kg/t)

2006 2007 2008 2009 2010

3.6 Waste

The types of waste produced inside the Group sites basically fall into three main categories:• originating from production:

- pulper waste- paper sludge

• hazardous waste:- batteries- used oils

• other types of non-hazardous waste:- scrap metal- special waste, also similar to urban waste, originating from production, which is disposed of using authorised disposal agencies- sludge from the water treatment plant- plastic packaging - wood packaging

The largest quantity of waste that is generated is production cycle waste and is therefore caused by the use of recycled paper at Porcari, Diecimo and Laval sur Vologne. In the first treatment process phase of recycled paper, the waste known as pulper is produced. This contains staples, plastic, adhesive bindings and other coarse substances which cannot be recycled. This type of waste is sent to the tip or to special disposal areas. But the next treatment phase produces the so-called paper sludge, composed of cellulose fibres which are too small to be re-used, mineral fillers (mineral substances found in the fresh or recycled fibre) and ink residues.The technology developed by Lucart Group for the transformation process of Tetra Pak containers can be recycled into other activities including manufacturing of plastic parts and aluminium residue, which then become secondary raw materials (each container, on average, is composed of 74% cardboard, 22% polyethylene and 4% aluminium) and it is for this reason that this process is also referred to “zero waste”.

Waste originating from production (t/1000)

Destination of the paper sludge in 2010*

Compost24.1%

Distribution onto agriculture fields (**) 13.5%

Construction products0.4%

(*) Porcari, Diecimo and Laval sur Vologne sites.

(**) This destination is usable only in France.

Brick production33.6%

Environmental recovery areas 28.3%

34 35

Porcari Diecimo Laval sur Vologne

2006 2007 2008 2009 2010

sludge sludge sludgepulper pulper pulper

36 37

In relation to both the total quantity of paper produced and the total amount of waste, the quantity of hazardous waste that is produced is very low. This type of waste can, in fact, be traced back to used oils, used batteries and other materials used for maintenance within the company.

Total quantity of waste produced at the Group sites (t/1000)

The management of all the types of waste follows strict procedures in accordance with the environmental management system. Also, in the offices, both paper and used IT materials (printer toner, ink, and hardware no longer in use) are collected and disposed of separately.

2006 2007 2008 2009 2010

38 39

3.7 Transportation

Total number of incoming/outgoing vehicles in relation to tonnes of paper sold (n/t x 1000)

Various types of transport, through external suppliers, are involved with production at Lucart Group sites (supplying raw and auxiliary materials, delivering the finished products, disposal of paper sludge etc.).

The environmental issues tied to transportation relate to air emissions, noise and energy consumption, and, in particular, the use of fossil fuels.

The data clearly shows that the number of vehicles that are used is strongly influenced by the type of finished product that is transported. The bulkier the product, as in the case of the tissue products, the greater the number of vehicles necessary.

In line with our Company Mission and transport service providers it has been decided to prioritize the increased use of vehicles with lower emissions. In particular, the company’s goal was to reduce the utilization of EURO3 vehicles over a period of three years by 10%. That objective was fully met in 2010.To try to limit the number of vehicles on the roads, railways were built directly inside of the Diecimo and Troyes production sites. Transport to and from the plants can therefore take place on rail rather than road, reducing traffic as well as the consequential emissions of pollutants from heavy vehicles.

2006 2007 2008 2009 2010

Diecimo 1,609 1,134 1,483 697 213

Troyes 130 154 173 71 24

Total number of wagons arriving at/leaving the internal railway yards (n)

2006 2007 2008 2009 2010

Over the past two years, unfortunately, the use of trains has decreased significantly. This can be attributed to the following reasons:

• Increase in costs of rail transport, which are equal to and sometimes greater than those of road transport.

• New “Translated”* costs tied to bringing wagons to private sidings.• Elimination of traffic “spread”* (that is, individual cars) by Trenitalia / RFI.• Limited availability of trains with the appropriate characteristics in the area (Lucca).• Poor level of service

HEALTH AND SAFETY

Ensuring the health and safety of workers is of fundamental importance for all organisations and their employees. One of Lucart Group’s main objectives of is to guarantee high standards of health and safety in the workplace. This common objective is implemented through a structured approach, which identifies the dangers and eliminates/reduces all working risks.

04

42 43

In all activities affecting health and safety in the workplace, the employees and their Safety Representatives are consistently involved with formal meetings and informal contacts.The documentation regarding the activities is described in detail in the Risk Assessment Document.

Accidents are statistically controlled recording how the accident occurred, the diagnosis, the parts of the body that were affected, the workdays that were lost and the qualitative data regarding the events of the accident. The following two rates are also assessed and monitored:

• Frequency rate (FR), equal to the ratio between the sum of the total number of accidents (indemnified by INAIL [the Italian Workers’ Compensation Authority] for durations of more than 3 days) and hours worked.

FR = (total n° accidents/hours worked) x 1,000,000

• Severity rate (SR), equal to the ratio between lost workdays and hours worked. SR = (n° lost workdays/hours worked) x 1000.

2006 2007 2008 2009 2010Porcari

FR 26.2 40.3 33.8 31.7 45.7

SR 0.9 0.7 1.1 0.5 1.3

Average duration of absence from work 33.3 16.8 32.5 14.2 27.8

Diecimo

FR 81.5 40.2 48.2 37.03 25.94

SR 1.1 1.6 1.2 0.90 0.85

Average duration of absence from work 13 39.1 23.9 24.39 33.06

Troyes

FR 57.4 41.5 32.6 57.78 55.04

SR 1.0 0.5 0.5 1.34 2.01

Average duration of absence from work 18.3 11.5 14.2 18 34.4

Torre di Mosto

FR == == 40.6 43.6 83.8

SR == == 0.26 3.28 3.22

Average duration of absence from work == == 6.5 75 38.44

Laval sur Vologne

FR == == == 33.9 30.78

SR == == == 1.55 1.25

Average duration of absence from work == == == 45.6 38.6

Accident rates

In 2010 the Diecimo, Porcari and Torre di Mosto production facilities joined the “ Target Zero - Safety Project ”, organized by the Foundation Joseph Lazzareschi in collaboration with Assocarta, and the Association of Industrialists of the Province of Lucca, thereby demonstrating their strong commitment and attention to issues relating to health and safety of their personnel.This commitment is also evidenced by the annual employee training and information sessions.

In 2010 the Diecimo and Porcari production facilities and have adopted a Safety Management System (certified according to the INAIL SGSL: 2001 guidelines) that allows us to monitor and control all the dynamics of internal safety in accordance with current legislative requirements.To perfect the steps taken in 2010, the Italian operations of Lucart Group are currently undergoing certification procedures (OHSAS 18001) in order to be certified by a third party as observers of legal compliance and as having a management system for work activities regarding health and safety at work.

“Target Zero” Safety Project

Safety certifications

05

PLANT DATA TABLES

46 47

PORCARI u. m. 2006 2007 2008 2009 2010

Total site production t 88,575 86,687 89,957 86,484 89,105

Water:

- Water used m3 593,288 578,763 581,870 485,170 560,790

- Discharged Water m3 442,857 424,270 434,700 335,163 409,677

Discharged water indicators:

- COD mg/l 560 704 685 569 482

- Suspended solids mg/l 170 239 159 121 83

- Total nitrogen mg/l 13.7 10.5 7.4 5.1 4.4

- Total phosphorous mg/l 0.4 0.3 0.4 0.9 0.8

Energy:

- Methane gas scm 43,816,460 42,191,827 42,360,284 40,586,272 43,455,354

- Electrical energy MWh 102,203 98,130 100,600 96,778 100,568

Raw materials:

- Total raw materials t 126,608 125,060 132,570 126,784 129,794

Emissions

- CO2 t 85,689 82,511 83,426 79,024 84,612

Emissions from energy production

- CO t 41 36 39 24 13

- NOx t 101 117 118 107 126

Solid waste:

- paper sludge t 46,282 45,878 47,812 43,116 41,700

- pulper waste t 3,356 2,644 2,477 3,322 3,737

- other non-hazardous t 613 796 1,100 1,574 1,395

- hazardous t 4.92 10.30 12.93 13.63 30.93

Transport:

- Total number of incoming/outgoing vehicles

n 11,359 11,239 11,085 10,295 10,097

DIECIMO u. m. 2006 2007 2008 2009 2010


Water:

- Water used m3 1,863,050 1,763,490 1,673,180 1,666,260 1,653,630

- Discharged Water m3 1,768,078 1,687,747 1,585,021 1,657,555 1,588,669


- COD mg/l 62 31 33 39 53

- Suspended solids mg/l 5.5 5.5 8 8 10



Energy:

- Methane gas scm 36,502,531 39,680,745 39,457,576 38,571,737 39,446,335


Raw materials:


Emissions

- CO2 t 71,386 77,601 77,709 75,102 76,805


- CO t 34.7 7.5 4.7 2.3 1.6

- NOx t 48 87 89 94 100

Solid waste:

- paper sludge t 48,174 21,067 19,135 8,956 5,745

- pulper waste t 2,467 1,321 960 1,102 2,530

- other non-hazardous t 761 1,115 1,570 1,827 1,925

- hazardous t 7 11 10 13 21

Transport:


n 24,058 22,689 21,799 20,420 20,719

- Total number of incoming/outgoing wagons

n 1,609 1,134 1,483 697 213

Porcari Site - quantitative data Diecimo site - quantitative data

48 49

Troyes Site - quantitative data Laval sur Vologne Site - quantitative data

TROYES u. m. 2006 2007 2008 2009 2010


Water:

- Water used m3 378,775 375,187 304,742 276,704 252,489

- Discharged water m3 298,437 287,891 226,922 196,118 175,243


- COD mg/l 248 225 299 450 448

- Suspended solids mg/l 92 51 68 94 95



Energy:

- Methane gas scm 6,263,600 6,632,850 6,803,110 6,793,914 6,397,120


Raw materials:


Emissions

- CO2 t 13,242 14,016 14,345 14,282 14,206


- CO t 0.12 0.13 0.13 0.13 0.13

- NOx t 14 15 15 15 15

Solid waste:

- non-hazardous t 583,26 527,9 733,4 573,9 675,8

- hazardous t 0.52 16.46 5.55 40.83 46.41

Transport:


n 7,926 8,231 8,758 8,549 8,387

- Total number of incoming/outgoing wagons

n 130 154 173 71 24

LAVAL SUR VOLOGNE u. m. 2009 2010

Total site production t 36,851 43,816

Water:

- Water used m3 655,710 752,480

- Discharged water m3 1,120,413 1,129,781


- COD mg/l 154 169

- Suspended solids mg/l 23.8 35.3

- Total nitrogen mg/l 4.6 5.7

- Total phosphorous mg/l 0.44 1.1

Energy:

- Methane gas scm 19,750,000 20,440,000

- Electrical energy MWh 44,532 51,144

Raw materials:

- Total raw materials t 54,470 61,981

Emissions

- CO2 t 18,897 22,475


- CO t 0 0

- NOx t 11 9.7

Solid waste:

- paper sludge 41,290 36,071

- pulper waste 3,498 4,688

- other non-hazardous t 44,958 41,045

- hazardous t 2.5 2.1

Transport:


n 8,196 10,609

50 51

Torre di Mosto site - quantitative data

FATO PROFESSIONAL u.m. 2008 2009 2010

Total site production t 5,579 6,234 7,404

Water:

- Water used m3 910 1,010 1,481

- Discharged water m3 0 0 0

Energy:

- Methane gas scm 117,565 117,818 71,606

- Electrical energy MWh 128 139 183

Solid waste:

- non-hazardous t 179 434 464

- hazardous t 8.5 9.5 11.2

Transport:


n 1,980 2,440 2,880

Via Ciarpi,77I - 55016 Porcari - LuccaTel. +39 05832140Fax +39 [email protected]

Zona IndustrialeI - 55020 Diecimo - LuccaTel. +39 058383701Fax + 39 [email protected]

Z.I. de Torvilliers R.N. 60F - 10440 La Rivière de CorpsTel. +33 (0)3 25790606Fax +33 (0)3 [email protected]

10, Rue Maurice Mougeot BP35F - 88600 Laval sur VologneTel. +33 (0)3 29557878Fax +33 (0)3 [email protected]

C/Trafalgar, 4 10° AE - 08010 BarcelonaTel. +34 932680440Fax +34 [email protected]

Via G. Galilei, 4Loc. Pontetezze - Z.I.I - 30020 Torre di Mosto (Venezia)Tel. +39 0421312811Fax +39 [email protected]

Cartiera Lucchese spa

Lucart France sas

Novatissue sas

Lucart Ibérica slu

Fato Professional spa

52 53

www.lucartgroup.com

This document has been made with Fedrigoni Freelife Cento paper produced from 100% recycled fibres, FSC and Ecolabel certified.Printed in June 2011

2010 environmental report - lucart group · 3.2 raw materials 3.3 water ... all data shown in the...

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