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1 Greetings
Kansai Paint Co., Ltd. understands that environmental
issues are so important, that we need to confront these with
appropriate solutions as part of our business activities.
Examples of our efforts are described in environmental
reports, which we have published annually since 1997.
This, the Environmental Report 2004 complies with the
Environmental Report Guidelines (2003) issued by the
Ministry of the Environment. Additionally, we have attempted
to enhance the contents of the report and disclose more
information regarding environmental and social issues, in
response to the survey results regarding last year's Report.
We hope to hear your opinions and comments on both our
activities, and on the information disclosed in this Report.
Editorial policy
Our mission is to preserve the global environment.
We act, achieve, and challenge.
We carry out our commitment to society with "transparent" management.
As regards preservation of the global environment, we understand our
responsibilities as a coating material manufacturer. We conduct our
business with a consistent philosophy throughout the R&D, material
procurement, manufacturing, sales, and after-sale service divisions, of it
being essential to maintain our established corporate policy and employee
consciousness toward the environment.
We are striving to achieve our fundamental mission of "protecting
resources, preserving the environment, and both building and maintaining
a prosperous society," and on top of this, we are promoting a range of
research and development with the main purpose of reducing the burden on
the environment.
While we carry out our business in full compliance with environmental laws and regulations, we see these environmental
problems as a big business chance in which we can exploit our professional technical capabilities. We have been
promoting a company-wide ISO campaign that includes the technical section, headquarters, and manufacturing
plants, and each operating location has successfully obtained ISO14001 certification. In particular, we have compiled
a thorough "voluntary action plan" that prevents manufacturing plants from generating waste, and we are also
successfully operating newly developed processing systems for waste paints and solvents. Our efforts focus on solving
environmental problems within our organization, in order that we can be a truly ecological company.
Regarding the development of coating materials, one of our largest business chances lies in water-based coatings for
motor vehicles, and we are approaching this from two directions: coating materials, and coating systems. This approach
has resulted in a smooth transition to water-based coating systems, thanks to joint development with automobile
manufacturers both within Japan and overseas. In architecture, coatings to counter sick house syndrome (illnesses
arising from indoor air pollution) have been selling well, bolstered by better understanding of this social problem.
In other fields, we have started to develop a coating material that has solar cell functionality, which uses clean sunlight
energy, and we have already announced some of our achievements in newspapers.
Our environmental activities have been described in detail in the Environmental Report 2004, that can also be browsed at
our homepage.
Kansai Paint Group continues its utmost efforts to protect our environment, and to disclose related information in order
that our activities are widely understood. We thank your continued support and feedback.
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Our aim - to be a company that nurtures the environment through environmental management
June 2004 President
Katsuya Sera
【Related fields】
Environmental aspects and social aspects
【Period】
Data provided herein has been collected in the period
between April 1, 2003 and March 31, 2004. (Latest data
as of April 2004 provided in part.)
【Scope】
Domestic activities by Kansai Paint Co., Ltd. including those
of some affiliated companies
Manufacturing sites*: Amagasaki Plant, Ono Plant, Nagoya
Plant, Hiratsuka Plant, Kanuma Plant
Non-manufacturing sites*: Tokyo Office, R&D Center,
Head Office
(*Including related companies located at the above business sites)
Others: Some affiliated companies
【Future publication plans】
June 2005 (Japanese version)
September 2005 (English version)
1 Greetings
2 Corporate Data
3 Business Locations
4 Environmental Management 1. Corporate Policy on Environmental Conservation
2. Activities for Responsible Care (RC) and Coating Care
3. Environmental Conservation (Responsible Care) Organization Chart
4. ALES ECO PLAN 2005 (2003 environmental goals and list of achievements)
5. Environmental Accounting
6. Development of Environment-Friendly Technologies
7. MSDS
8. Container Yellow Card
5 Environmental Management System (ISO14001) List of Certified Kansai Paint Group Business Establishments
6 Business Activities to Reduce the Environmental Burden 1. Environmental Material Balance
2. Energy Saving and the Prevention of Global Warming
3. Measures to Reduce Water Resource Input
4. Waste Reduction (Reduce, Recycle, Reuse)
5. Management of Chemical Substances
6. PRTR Substances' Release and Transfer
7. Life Cycle Assessment (LCA) Initiatives
8. Eco-Product Ratio
7 Social Efforts Safety and Health Activities
Contents
3 4
2 Corporate Data (As of March 31, 2004) 3 Business Locations
0
1,000
2,000
3,000
4,000
5,000
6,000
7,000
8,000
����
���� �� ����������
'00 '01 '02 '03
������������ ��������������������� �����
���������� �������� ������ ���� ��� ����������49.1%
���������� ��������22.6%
���������� ��������22.8%
������ ��� ������������������5.5%
2003
49.1%
22.8%
5.5
%
22.6%
Head Office
(Chuo-ku, Osaka)
R&D Center
(Hiratsuka, Kanagawa)
Amagasaki Plant
(Amagasaki, Hyogo)
Tokyo Technical & Business Office
(Ohta-ku, Tokyo)
Ono Plant
(Ono, Hyogo)
Tokyo Office
(Shinagawa-ku, Tokyo)
Nagoya Plant
(Miyoshi-cho, Aichi)
Kanuma Plant
(Kanuma, Tochigi)
Hiratsuka Plant
(Hiratsuka, Kanagawa)
Domestic
0
2,000
4,000
6,000
8,000
10,000������������ ��������������������� �����
����
��������� �� ����
'00'99 '01 '02 '03
0
50,000
100,000
150,000
200,000
250,000
����
��������� �� ����
'00'99 '01 '02 '03
������������ ��������������������� �����
Net sales
Net income
Consolidated sales breakdown by products
Number of employees
Date of Establishment May 17,1918
Capital ¥25,658 million
Number of Employees5,886 (Consolidated)
1,882 (Non-Consolidated)
URL http://www.kansai.co.jp
KANSAI PAINT CO., LTD.
Major Business Locations
Domestic Subsidiaries and Affiliates
Overseas Subsidiaries and Affiliates
Head Office3-6, Fushimi-machi 4-chome, Chuo-ku,
Osaka 541-8523, Japan
Offices Tokyo, Kita-Kyushu
Sales OfficesFukuoka, Hiroshima, Osaka, Nagoya,
Tokyo, Kita-Kanto and others
PlantsAmagasaki, Ono, Nagoya, Hiratsuka,
Kanuma
R&D Center Hiratsuka
(Trade Sales Coatings Group)・KANSAI PAINT SALES CO., LTD.
・KANPE KYOHAN HOKKAIDO CO., LTD.
・KANPE KYOHAN SHIKOKU CO., LTD.
・KANPE KYOHAN KYUSHU CO., LTD.
・NOF KANSAI MARINE COATINGS CO., LTD.
・MIYACHI KASEI CO., LTD.
(Industrial Coatings Group)
(Manufacturing Group)
(Color Matching Group)
・KANPE TRADING CO., LTD.
・KANPE AUTOMOTIVE COATINGS TRADING CO., LTD.
・OHGI SHOKAI CO., LTD.
・NIPPON KAKO TORYO CO., LTD.
・KANPE MIYOSHI COLOR CENTER CO., LTD.
・UTSUNOMIYA CHEMICAL CO., LTD.
・MIYOSHI CHEMICALS, INC.
・KUBOKO PAINT CO., LTD.
・KANPE SERVICE CO., LTD.
・KANPE KANAGAWA COLOR CENTER CO., LTD.
・KANPE ONOMICHI COLOR CENTER CO., LTD.
・KANPE KEIYO COLOR CENTER CO., LTD.
(Shipping Storage)・KANUMA STOREHOUSE CO., LTD.
(Domestic Business Group)・KANPE HAPIO CO., LTD.
・KP WING CO., LTD.
・KANSAI PAINT ENGINEERING CO., LTD.
・KANPE PLANT ENGINEERING CO., LTD.
・KP FINANCE CO., LTD.
・ECO SYSTEMS CO., LTD.
・GOODLASS NEROLAC PAINTS LTD.
・P.T. KANSAI PAINT INDONESIA
・KANSAI PAINT (SINGAPORE) PTE. LTD.
・KANSAI PAINT (ASIA) PTE. LTD.
・SIME KANSAI PAINTS SDN. BHD.
・THAI KANSAI PAINT CO., LTD.
・KANSAI RESIN (THAILAND) CO., LTD.
・KANSAI PAINT PHILIPPINES, INC.
・TAIWAN KANSAI PAINT CO., LTD.
・KANSAI PAINT H.K. LTD.
・TIANJIN COSCO KANSAI PAINT & CHEMICALS CO., LTD.
・SHENYANG KANSAI PAINT CO., LTD.
・SHANGHAI COSCO KANSAI PAINT & CHEMICALS CO., LTD.
・HUNAN KANSAI AUTOMOTIVE COATINGS CO., LTD.
・CHONGQING KANSAI PAINT CO., LTD.
・TIANJIN BEACON KANSAI PAINT CO., LTD.
・KANSAI PAINT (AMERICA), INC.
・DU PONT-KANSAI AUTOMOTIVE COATINGS, CO.
・KANSAI PAINT EUROPE LIMITED
・DU PONT-KANSAI AUTOMOTIVE COATINGS (U.K.) LIMITED
(America)
(Europe)
(Asia)
5 6
Action Policy
Operational Policy
1. Corporate Policy on Environmental Conservation
3 Business Locations 4 Environmental Management
Shenyang Kansai Paint Co., Ltd.
(China)
Shanghai Cosco Kansai Paint &
Chemicals Co., Ltd.
(China)
Sime Kansai Paints Sdn. Bhd.
(Malaysia)
Tianjin Beacon Kansai Paint Co., Ltd.
(China)
Taiwan Kansai Paint Co., Ltd.
(Taiwan)
Kansai Paint (Singapore) Pte. Ltd.
(Singapore)
Tianjin Cosco Kansai Paint &
Chemicals Co., Ltd.
(China)
Thai Kansai Paint Co., Ltd.
(Thailand)
P.T. Kansai Paint Indonesia
(Indonesia)
Chongqing Kansai Paint Co., Ltd.
(China)
Kansai Resin (Thailand) Co., Ltd.
(Thailand)
Goodlass Nerolac Paints Ltd.
(India)
Hunan Kansai Automotive Coatings Co., Ltd.
(China)
In order to achieve our goals concerning protection of the global environment, our company and its employees
cooperatively promote Responsible Care based on the Action Policy.
December 21, 1992
President's Notice No. 80
Kansai Paint and our Group companies are fully aware
of our responsibilities as a social entities, and of our
mission as paint manufacturers. We have established
the following as our basic policies. These policies aim
to secure the protection of the global environment and
ensure human health and safety, while at the same time
living up to expectations of society through positive
participation and contributions.
Basic Policy
Corporate Mission
Overseas
Corporate Policy on Environmental Conservation
To supply products after full consideration of their potential impacts on people and the environment.
To undertake proactive countermeasures to cope with the potential effects of products on people and the
environment.
To cooperate with external organizations to raise awareness concerning the environment, safety, and
health.
To disclose and provide information related to the environment, safety, and health.
1.
2.
3.
4.
To develop new technologies and products with a focus on the maintenance and promotion of environment-
friendliness, and the protection of natural resources.
To promote the wider use of products with a reduced load on the environment.
To reduce waste, and promote recycling and resource recovery.
To reduce energy use and carbon dioxide emissions.
To secure the environment, safety, and health of the workplace, and to reduce solvent emissions.
To strive for the prevention of environmental/safety/health problems stemming from customers' use of
our products.
To educate our employees and related companies regarding environmental/safety/health problems.
To promote Green Procurement, and to promote the purchase of Green Products.
To issue environmental reports.
To disclose environmental/safety/health information regarding our products.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
To further build company credibility with the public and to
contribute to society, by providing products and services
that achieve customer satisfaction.
To build on our knowledge and strive for technological
innovations, in order to improve the company's performance.
To harness the collective efforts of all individuals,
to maximize the company returns.
1.
2.
3.
7 8
2. Activities for Responsible Care (RC) and Coating Care 3. Environmental Conservation (Responsible Care) Organization Chart
4 Environmental Management 4 Environmental Management
The paint industry calls Responsible Care "Coating
Care," which is one of the activities of the International
Paint & Printing Ink Industry Council (IPPIC). Coating
Care was established in 1992 by seven Manufacturer's
Associations in six countries. The principles of Coating
Care are to promote effective health, safety and
environmental practices through the entire life cycle of
products, from the design stage through to disposal.
In January 2001, Kansai Paint
declared their implementation
of Coating Care, and we are
currently promoting activities
toward this end.
Main activities of Responsible Care
Coating Care
Responsible Care Organization
Environmental ISO 14001 Organization
Kansai Paint Co., Ltd. is a member of the Japan
Chemical Industry Association and Japan Paint Industry
Association. Chemical substances are vital elements in
our lives, however, handing such substances requires
careful consideration in terms of their environmental
burden, personal safety, and personal health.
Chemical industries worldwide are engaging in voluntary
activities to protect our environment, safety, and health
through the entire cycle - from development of chemical
substances through to their disposal.
At Kansai Paint, this kind of voluntary activity is called
the ALES ECO PLAN, under which Responsible Care and
Coating Care are being exercised.
Kansai Paint's declaration for Coating Care
RC Management Review
RC Committee for Company-wide Promotion of Quality Control and Environmental Protection
RC Environmental & Product Safety Committee
RC Environmental Safety/Health Committee
RC User- & Customer-related Environmental Safety Committee
RC Committee
Quality/Environment Officer: Managing Director
Secretariat
Product Quality & Environment Division
Committee Chair: President
[Activities] [Activities] [Activities]��������� �� ������������� ����
�������� �������������
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������� ���� �������������� ������� ��� �������� ���������
Automotive Coatings Division
Automotive Refinishes Coatings Division
Industrial Coatings Division
Decorative Coatings Division
Anticorrosive Coatings Division
New Business Division
SD Center
AT Laboratory
CM Laboratory
Technical Planning Department
Energy Conservation Team
Waste Reduction Team
Health Subcommittee
Plants
Business Planning & Administration Division
Information Systems Department
Procurement Division
Supply Chain Management Center
�������� ��� �������� ��� ����� ���������� ��� ���������
������� ���� �������������� ������� �������� ���������
����������
Environment management review by top management of ISO organization
External Audit
Internal Environmental Audit
Head Office
R&D Center
Amagasaki Plant
Ono Plant
Nagoya Plant
Hiratsuka Plant
Kanuma Plant
Tokyo Technical & Business Office
[Activities]������������� �������
������ ����������
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Communication
Occupational Health and Safety
Chemical and Product Safety
Environmental Preservation
Process Safety and Accident Prevention
Society
ICCA(International Council of Chemical Association)
(Responsible Care)
IPPIC(International Paint & Printing Ink Council)
(Coating Care)
Japan Chemical Industry Association (members: 188 companies & 77 groups)
Japan Paint Industry Association(members: 105 companies & 2 groups)
Coating Care(instituted in 1992)
Japaneseassociations
Internationalassociations
Kansai Paint
ALES ECO PLAN 2005
Japan Responsible Care Council(established in 1995)
Responsible Care declaration (1995)
Coating Care declaration (2002)
Join Join
Join Join
It is recognized that regulations alone can not completely
ensure environmental-friendliness, human safety, and
health. In response to current demands, the world's
chemical industries have begun working on self-imposed
controls to protect the environment,
safety, and health at all stages of
chemical processing, f rom their
development right through to their
disposal . This activ ity is called
"Responsible Care."
Responsible Care
9 10
4. ALES ECO PLAN 2005 (2003 environmental goals and list of achievements)
4 Environmental Management
Activities Objectives 2005 Target 2003 Target 2003 Achievements Evaluation* 2004 Target
To provide products after full consideration of their impact on people and the environment
1.Development of
environment-
friendly
products and
technologies
1) 1st stage reduction materials Reduce usage to 0 50% or more reduction from FY'02 42% (achievement ratio: 84%) ○ Eliminate completely by the end of FY'04
2) Xylene/Toluene usageReduce usage to 18,500 t/yr or
less
20% or more reduction from FY'02
(Reduce usage from 27,900 t to 22,300 t)2% (achievement ratio: 10%) △ Reduce usage to 22,000 t/yr or less
3) Chromium (VI) compounds
usageReduce usage to 149 t/yr or less
40% or more reduction from FY'02
(Reduce usage from 478 t to 287 t)7.2% (achievement ratio: 18%) △ Reduce usage to 225 t/yr or less
4) Lead compounds usage Reduce usage to 241 t/yr or less35% or more reduction from FY'02
(Reduce usage from 732 t to 476 t)419 tons (target achieved) ◎ Reduce usage to 350 t/yr or less
5) Nonylphenol compounds Reduce usage to 1 t/yr or less Reduce usage to 5 t/yr or less 4.2 tons (target achieved) ◎ Reduce usage to 2 t/yr or less
2. Promoting
the usage of
products with
a reduced
environmental
burden
1) Environment-friendly products
ratioEco-products 60% or higher Increase to 48%, 5% up from FY'02 48% (target achieved) ◎ Eco-products 54% or higher
2) Anti-"sick-house syndrome"
coatings
Expand compliant product lines,
including industrial paints
Expand product lines that conform to the Revised
Building Standard Law
Almost completed product lineup for F ☆☆☆☆ and
other classes ○
Expand product lines that conform to the Revised Building
Standard Law
3) Eco-paints for architecture Expand eco-coating product lines Increase volume of eco-products 30% over FY'02 Target achieved ◎ Continue to release environment-friendly products
To undertake proactive measures to remove potential effects of products on people and the environment, and to enhance awareness and cooperation
3. Reduction of
environmental
burden in
operations
1) Energy consumption 2.0% or more reduction from FY'01 1.0% or more reduction from FY'01 0.6% reduction from FY'01 (achievement ratio: 60%) △ 1.5% or more reduction from FY'01
2) CO2 emissions 2.0% or more reduction from FY'01 1.0% or more reduction from FY'01 1.2% reduction from FY'01 (target achieved) ◎ 1.5% or more reduction from FY'01
3) Waste emissions
(final landfill amount)Zero-emissions achieved by 5 plants 45.0% or more reduction from FY'01 46.1% reduction from FY'01 (target achieved) ◎ 67.5% or more reduction from FY'01
4) Waste recycling ratio 99% or more of waste generated 95% or more of waste generated in FY'03 96% (target achieved, some reached 100%) ◎ 97.5% or more of waste generated in FY'04
4. Securing
Safety and
Health
1) Number of accidents Aim for zero accidentsEliminate lost-work accidents, and ensure no
accidents or injuries
9 accidents, including 1 lost-work accident, an increase
from 6 last year△ Eliminate lost-work accidents, and ensure no accidents or injuries
2) Workplace environment regarding
organic solvent exposure
Maintains zero Class-2 and -3
workplacesTotal elimination of Class-2 and -3 workplaces One Class-3 workplace △ Total elimination of Class-2 and -3 workplaces
3) Mental health careAim for zero patients with mental
injuries
Promote "health and sanitation subcommittee
meeting" activities, and implement company-wide
and employee education
Instituted mental health operating procedures. Conducted
mental health educational seminars at each business site◎ Promote better understanding of mental health care handling
5. Environmental
Conservation
Activities
1) ISO 14001 activitiesAim for company-wide integrated
activities
Promote new certification of group companies
while keeping maintenance activities
Status maintained or updated by certified plants/offices,
One affiliate company certified in April 2004◎ Consider company-wide integrated activities
2) Preparation of environmental
accountingContinue preparation
Continue to prepare company-wide environmental
accounting (5th edition)Disclosed in Environmental Report 2003 ◎
Continue to prepare company-wide environmental accounting
(6th edition)
3) Ensuring transportation safety Aim for continued full complianceContinued implementation of Container Yellow
Card system
New labeling system implemented
(40% implementation)◎ Full implementation of new labeling system by the end of FY'04
4) Prevention of environmental
pollutionAim for zero complaints
Give top priority to compliance, in order to prevent
pollution and complaintsZero environment-related claims ◎
Give top priority to compliance, in order to prevent pollution and
complaints
6. User- &
Customer-
related
Environmental
Safety
1) Improve the MSDS system Continue timely issuanceImprove systems for faster data supply for MSDS
issuanceHabitual web downloading implemented ◎ Further implementation of advanced data supply systems
2) Improve the PRTR systemOngoing compliance with laws and
regulations
Educate and promote use of the system in Color
Centers (total 35 locations)Color Centers submitted PRTR substances ◎ Improve the PRTR handling system
3) Prevent Product Liability claimsContinue with zero product liability
claims
Take proactive measures against potential
product liability issues, for zero claimsZero PL-related claims ◎
Take proactive measures against potential product liability
issues, for zero claims
7. Disclosure of
Environmental
Information
1) Risk communicationContinue meetings to explain legal
compliance
Continue to hold seminars for distributors, clients,
and administrative agencies regarding law
compliance and coating materials.
50 or more meetings held nationwide ◎
Continue to hold seminars for distributors, clients, and
administrative agencies, regarding law compliance and coating
materials.
2) Publish an "Environmental
Report"Implement continued publishing
Continue issuance of the "Environmental Report
2003" (Japanese 7th year, English 2nd year)
Environmental Report 2003: Japanese and English
versions issued in June and October respectively◎
Continue issuance of the "Environmental Report 2004"
(Japanese 8th year, English 3rd year)
3) Publish an "Annual Report" Implement continued publishing Continue issuance of the "Annual Report" Annual Report 2003 issued ◎ Continue issuance of the "Annual Report"
*【Achievement level】 ◎ : Approximately 100% or higher ○ : 70% or higher △ : Less than 70%
11 12
The cost of environmental conservation in FY2003
amounted to 4,794 million yen, divided between 283
million yen for capital investment, and 4,511 million yen
for operating costs. (These costs in FY2002 were
4,682 million yen, comprising 397 million yen for capital
investment, and 4,285 million yen for operating costs.)
The capital investment for facilities has dropped by
114 million yen from FY2002, but there has not been
a significant change in the operating costs for our
activities. However, there has been an increase in the
amount of environment-related research carried out by
the R&D Center, resulting in an increase in R&D costs
of 230 million yen over FY2002.
5. Environmental Accounting
4 Environmental Management
Kansai Paint deems environmental activities an
important tool for assisting management, and has been
implementing environmental accounting since 1999,
with the purpose of keeping a good balance between
operating costs incurred by environmental activities,
and environmental conservation effect and economic
activities.
1. Complies with the Environmental Accounting Guidelines 2002 issued by Japan's Ministry of the Environment.
2. Calculates the investment amount for environmental conservation activities and operating costs (including
depreciation), and their effects.
3. Calculates the environmental effect of business activities (physical units) and economic effects of
environmental measures (monetary units).
4. Scope of accounting: five plants, Tokyo Office and R&D Center.
5. Period: April 1, 2003 to March 31, 2004
Category
FY2003
Main activitiesInvestment
Operating
costsTotal
In-house
activities
Pollution
prevention102 244 346
Investment and operating costs required for prevention of pollution
(atmosphere, water, noise, odors, vibration, etc.)
Global
environmental
preservation
104 550 654 Investment and operating costs required for energy savings and
the prevention of global warming
Waste disposal
and recycling67 527 594
Investment and operating costs required for waste reduction and
recycling
Administration costs 10 280 290
Development of environmental management systems
Disclosure of operational environment information
(publishing of environmental reports)
Cost for monitoring the environmental burden
Cost for greening and beautification
R&D costs 0 2,910 2,910 Investment and operating costs required for technical development,
with environmental friendliness as a primary target.
Total 283 4,511 4,794
1) Principles of Environmental Accounting 2003
2) Result of 2003 Activities
(units: million yen)
Progress in environmental conservation is shown
in the table by the reduced amount, and where the
environmental burden produced by our FY2003
business activities is compared with that of the previous
year.
The amount of resources used for business operations
were reduced in all categories when adjusted and
compared with figures for FY2002. Additionally,
quantities of environmental emissions and waste were
also reduced from FY2002 with the exception of one
category, namely soot and dust.
We calculated the economic effects of our environmental
conservation measures by comparing the financial
accounting income achieved in FY2003 with that of the
previous year.
An economic effect of 62 million yen was achieved by
energy-saving and water-saving measures in FY2003.
Waste processing costs, however, were increased by
nine million yen. As a result, a total of 530 million yen
worth of economic effect was achieved.
Since it was first published in 1999, the environmental accounting system has been improved to provide top
management with a better decision-making support tool. The system will be further enhanced to accurately
evaluate environmental management.
3) Environmental Conservation Results
4)Economic Effects of Environmental Conservation
Press release
Category Reductions
Resource conservation results in business activities
Energy usage (crude oil equivalent (kl))
CO2 emissions (tons)
1,110
2,810
Water usage (m3) 52,900
Environmental emissions and waste reduction in business activities
Air pollutants SOx(kg)
NOx(kg)
Soot and dust (kg)
Water pollutants COD(kg)
180
870
▲116
690
Industrial waste Generated (tons)
Externally contracted (tons)
403
283
Category Economic effects
Cost reductions
from energy savings in business locations 43
from reductions in water and sewerage costs 19
from reductions in waste processing costs ▲ 9
Total 53
Note) Economic effects from environmental conservation measures = Previous FY operating costs - Current FY operating costs.
R&D cost breakdown: [R&D costs by R&D Center] x [Research employee ratio] x [Environment-related research theme ratio]
Past environmental damage-related expenses are omitted because this amount was zero for both investment and operating costs.
Note) Effect of environmental conservation was calculated with the adjustment comparison method, compared with the production volume for FY2002 activities.
Effect of environmental conservation (reduced amount)=
[environmental burden of last year x (production of this year/production of last year)] - [environmental burden of this year]
(units: million yen)
13 14
6. Development of Environment-Friendly Technologies
4 Environmental Management
Kansai Paint's Basic Technologies Look to the Future
Kansai Paint's Core Technologies
Kansai Paint's core technologies are represented by
coatings, painting, and coloring technologies. These
element technologies are supported by core techniques
involving polymer synthesis, photochemistry, molecular
cross-linking, and coloring material technologies.
Kansai Paint is expanding its core technologies in
wider applications, in order to add much higher value to
products through surface modification.
Kansai Paint and its group companies have been
dealing with various environmental issues since they
made a declaration on Responsible Care in 1995,
based upon "Company policies regarding environmental
issues" from 1992. Our research themes have since
been focused around low environmental burden,
high-performance, and high-function products and
technologies (coatings materials and coating systems)
in order to conserve resources and the beauty of nature,
as well as to both prevent environmental pollution, and
to promote environmental protection. Our environment-
related research themes account for 70% of our
total R&D subjects, and these are closely connected
with environmental issues. Kansai Paint in the 21st
century aims to be a both corporate citizen and a global
citizen: thus, we sincerely hope that our R&D activities
contribute to the protection of the global environment.
Earth- and Living Environment-FriendlyEnvironment-Protective Coatings
Paintsfor Improving
Living environment
EnvironmentCleaningTechnology
Paint wasterecycle system
RecycleTechnology
ContainerRecycling
All the plants certified with ISO14001
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Kansai Paint R&D Center (Hiratsuka)
Benefits of the new coating system
1. Amounts of VOC are reduced, by using water-
borne intermediate coats and topcoats.
2. The bake process for the intermediate coat is
eliminated, and intermediate coat painting, base
coats, and clear coats are applied in the wet-on-
wet method, achieving shortened process length
and energy savings.
Automobile Coating System Reducing Process and VOC (Volatile Organic Compound)
Process New coating systemCurrent coating system
(using water-borne base coat)
Current coating system
(all solvent-based)
VOC amount (g/L)
Intermediate coat 100~ 200 450~ 550
Base coat 100~ 200 100~ 200 650~ 850
Clear coat 450~ 600
Process length from intermediate coat to
topcoat, excluding topcoat bake (meter)90~ 130 230~ 380 230~ 380
Kansai Paint combines its accumulated technologies
and new ideas in order to develop environmental-
friendly and safe products, and carries out technological
development to support these products.
In the automobile industry, solvent-based intermediate
coats and topcoats for motor vehicles are being
replaced by water-borne coatings to comply with the
VOC specifications and RPTR laws. We were proud to
say that we have successfully developed a water-borne
coating system that is kind to the environment.
Comparison between new and current coating systems
Coating layer of motor vehicles
Polymersynthesis
Polymercross-linking
Computersimulation
Light energy
Coloring materials
Biotechnology
Surfacecontrol
Engineering
Analysis
Rheologicalcontrol
Technologies to modify surfaces and to extremely increase the value of products
Pursue the ultimate in possibilities for coating materials
Develop new techniques and new fields based on coating technologies
Develop environment-friendly products
Application Coatings
Color and Design
High solid clear
・Smoothness・Durability, acid resistance
・Color designing
Water-borne base coat
・Chipping・Layer-mixing prevention technology
Water-borne intermediate coat
Solvent-based or water-borne base coat
Solvent-based intermediate coat
Clear coat
Cathodic electrodeposition coat
Bake
Bake
Bake
Pre-heat (water-borne)
Water-borne base coat
Intermediate coat
Clear coat
Cathodic electrodeposition coat
Bake
Bake
Pre-heat
Pre-heat
Current coating system New coating systemMain element technologies developed
Cathodic electrodeposition
Intermediate coat
Baking oven
Baking oven
Base coat (solvent-based or water-borne)
Pre-heat
Clear coat
Cathodic electrodeposition
Water-borne intermediate coat
Baking oven
Water-borne base coat
Pre-heat
Clear coat
Pre-heat
Shorter process length
New coating systemCurrent coating system
15 16
Coating does not contain lead or chrome compounds, or
endocrine disrupting chemicals that include nonyl phenol,
which is suspected of adversely affecting hormonal
activity in humans.
This turpentine soluble type coating offers superior
brushability equivalent to that of ordinary synthetic resin
paint, and excellent recoatability for very diverse prior
coating films. Furthermore, its solids content reduces
solvent volatilization into the atmosphere.
UNITECT SAFETY PROCESS-Environment-Friendly Process-Reduced Coating System-We have developed a new environment-friendly corrosion
protective coating system. UNITECT SAFETY offers
three types of solutions: UNITECT 10 SAFETY
PROCESS which is a conventional alkyd anticorrosion
coating system, UNITECT 20 SAFETY PROCESS which
is a heavy duty protective coating with performance
equal to that of polyurethane, and UNITECT 30 SAFETY
PROCESS which is a weathering heavy duty protective
coating with performance equivalent to that of silicone.
Features of UNITECT SAFETY PROCESS
Kind to humans and the environment
Mild solvent type and high solids contents
Example of UNITECT 30 SAFETY PRCESS
Resin ingredients with excellent weatherability migrate towards
the coat film surface. (ex. Silicone)
Corrosion resistanceAnticorrosive pigments and epoxy resin included
Environmental atmosphere interceptionResin ingredients form a network structure as they age, and intercept moisture, oxygen, etc.
Internal stressReduced shrinking stress during hardening
AdhesionPromoted through a special functional group in the resin
Architectural Coatings countering Sick-house Syndrome (indoor air pollution)-Measures to comply with Revised Building Standard Law-Sick-house syndrome, in which people become ill as a
result of chemical substances discharged by building
materials, has been an issue of national concern. To
counteract this problem, the Revised Building Standard
Law that regulates building materials that discharge
toxic VOC was enacted in July 2003, and all interior
materials containing paint are banned or regulated
according to their rate of formaldehyde emission.
All interior materials that can be used in living area
are classified as F (no usage limitations)
through F (usage limitations in living areas)
depending on their rate of formaldehyde emission.
Kansai Paint ensures it complies with the Revised
Building Standard Law, by having a third party inspection
agency measure our products' rate of formaldehyde
emission.
We have also developed various new products
supporting the Revised Building Standard Law, including
POWER FORCE, which is the first ready-mixed synthetic
resin paint certified as F . Representative anti-
sick-house paints are listed in the table at right, some of
which are new products.
Kansai Paint's anti-sick-house syndrome paints (for internal coating use)
Ministry of Land, Infrastructure and
Transport
Revised Building Standard Law (enacted in July 2003)Classifies construction materials by their rate of formaldehyde emissions
F ☆☆☆☆ Not regulated No usage limitations
F ☆☆☆ Class-3 construction material Usage limitations when painting living areas
F ☆☆ Class-2 construction material Usage limitations when painting living areas
No marking Class-1 construction material Usage prohibited in living areas
Ministry of Education, Culture, Sports,
Science and Technology
Revision of "School Environment Health Regulations"Measurements of concentrations of formaldehyde, toluene, xylene, and paradichlorobenzene in newly constructed or remodeled rooms are required. Delivery is granted when the specified values are achieved.
Ministry of Health, Labor and Welfare"Guidelines for Indoor Air Pollution"Indoor concentrations are specified for 13 chemicals including formaldehyde, toluene, and xylene.
Response of governmental authorities to "sick-house syndrome"
touch up
Acrylic silicone resin based topcoat 25 μm
Acrylic silicone resin based intermediate coat 30 μm
JIS epoxy type anti-corrosive 60 μm
Existing coating film
Substrate
Silicone resin coating system
touch up
UNITECT 30 SAFETY 60 μm
Epoxy type anti-corrosive (ESCO NB SAFETY) 60 μm
Existing coating film
Substrate
UNITECT 30 SAFETY PROCESS
In general, primers offer anticorrosive functions, and top
coats offer weatherability. Thus, two or three paints are
coated in conventional processes. UNITECT SAFETY
PROCESS offers double functional coatings that have
excellent anticorrosion and weatherability functionality,
meaning one coating process can be eliminated.
Cost reduction through process reduction
Feature of UNITECT 30 SAFETY coating film (comparison in single coat)
Corrosion resistance(combined cyclic corrosion test: 100 cycles) * Red line denotes blistering.
Thick-film type polyurethane resin coating 60 μm
Epoxy polyurethane resin coating 60 μm
UNITECT 30 SAFETY 60 μm
Tape
stripping
width
13 to 20 mm
Tape
stripping
width
2 to 4 mm
Tape
stripping
width
1 to 4 mm
Weatherability
0
20
40
60
80
100
0 300 500 1000 1500 2000
S-W-O-M exposure time (hours)
UNITECT 30 SAFETYSilicone systemPolyurethane system
60G gloss retention (%)
High
Low
Si
Surface layer
Lower layer
Coating film
Silicone orientation in the UNITECT 30 SAFETY coating film (Elemental analysis of Si by XMA)
Substrate Product name Product characteristics
Concrete/
Mortar
surfaces
Primer ECO CATION SEALER Chlorine-free
Topcoat
ECO DELUXE ⅡTVOC: 1.0% or lessFormaldehyde removed, antibacterial, deodorized
VINYDELUXE 300 TVOC: 1.0% or less
VINYDELUXE 500 TVOC: 1.0% or less
ALES ECO CLEAN GLOSSTVOC: 1.0% or lessLow VOC-type gloss emulsion
Iron
Primer AQUAMACS Hybrid of water based alkyd/water based epoxy resin
Topcoat
ALES ECO CLEAN GROSS ASKA ⅡTVOC: 1.0% or lessLow VOC-type gloss emulsion
POWER FORCE (F4)Double function type ready-mixed synthetic resin paintMild solvent type
Wood
Primer AQUA GROUNDCOAT TVOC: 1.0% or less (wood primer)
Topcoat
ECO DELUXE ⅡTVOC: 1.0% or lessFormaldehyde removed, antibacterial, deodorized
ALES ECO CLEAN GLOSSTVOC: 1.0% or lessLow VOC-type gloss emulsion
POWER FORCE (F4)Double function type ready mixed synthetic resin paintMild solvent type
Safety information No products use formaldehyde, toluene or xylene, or lead compounds.
Building Standard Law All products meet the requirement F ☆☆☆☆
17 18
People and Environment Friendly Sample Cards-Paints without endocrine disrupting chemicals, lead compounds, or chrome compounds-
There has been a growing concern in our society over
endocrine disrupting chemicals and heavy metals
including lead and chrome, which have adverse effects
on both the environment and human bodies.
To respond such problems, Kansai Paint has prepared
paint color sample cards that are friendly to the
environment and people.
These color sample cards enable color design of paint,
while containing no toxic or hazardous substances.
1. Does not include endocrine disrupting chemicals
that adversely affect humans.
2. Does not include lead and chrome compounds
that are harmful to humans.
3. Better drying and bending characteristics are
achieved for use in color sample cards.
4. Wider color variations.
Merits
"CELA M SILICONE II", Exterior Paint with high Weatherability and Low Staining-Innovative paint offering characteristics of both polyurethane and silicone-To prolong recoating period, exterior paints require high
weatherability and low staining characteristics. For
thinners, strong solvents such as toluene are being
replaced with mild solvents, that include mineral spirits.
Furthermore, solvent based paint has been switched
to waterborne paints. Under these circumstances,
Kansai Paint has been distributing the mild solvent type
silicone resin coating CELA M Silicone. Furthermore, we
are proud to announce the successful development of
new CELA M Silicone II with better weathering, and low
staining characteristics.
CELA M Silicone II was developed by applying urethane
cross-linking with conventional silicone resin paint. This
innovative product thus offers features achieved by both
polyurethane paint and silicone resin paint. Polyurethane
paint offers superior initial film performance and solvent
resistance, whereas silicone resin paint provides better
weathering and low staining characteristics.
Reaction of conventional silicone resin paint
Reaction of CELA M Silicone II
Urethane reaction
occurs at the initial
stage of hardening
followed by silicone
reaction, which form
firm crosslinks.
CELA M Silicone IIConventional solvent-type
polyurethane paint
Dif ficul t cont ro l
of the hardening
reaction rate.
Rain staining test
"BIG VAN SENSOR," New Sensor System for Color Matching-Color matching processes are streamlined using a huge database, and advanced CCM theory-Color matching requires special skills in the automobile
refinishing process, thus its efficiency affects the entire
refinishing process. The automobile refinishing industry
has been asking for an effective color matching tool with
which anybody from novices through to experienced
workers are able to achieve the same level of work
efficiency. Furthermore, Kansai Paint has utilized its
accumulated know-how and abundant knowledge in
successfully developing a system that can measure
brilliance and graininess of metallic color. Advanced color
matching accuracy was achieved by combining visual
analog information (metallic impression theory) and
digital information (CCM theory), and this new system
is expected to contribute to streamlining the color
matching process.
Five big advantages to the introduction of BIG VAN SENSOR
Merits of metallic impression theory
1. Even novices are able to perform color matching.
2. Provides color matching training functionality.
3. Latest formula and color matching information can be easily obtained.
4. Color matching processes can be standardized and split up.
5. Waste paint quantities are decreased.
Introduction to "Metallic impression theory"
Flat surface Textured surface Flat surface Textured surface
What is metallic impression theory?
Newly developed two-stage color matching process
Tinting
Customer's color sense and visual impressions are reflected in CCM (computerized color matching)!
Standard formula +
CK formula
First stage Second stage
Metallic impression sample
Formula
Formula
Formula
Formula
Formula
Formula
Formula
Formula
Formula
Formula
Formula
Formula
Formula
Formula
Formula
Formula
Selection by metallic impression theory
Actual Formula Actual vehicle color
The visual impression of metallic color is digitalized based upon its brilliance and graininess, and this data is stored in the database. Metallic impression theory is a process to improve color matching accuracy by using this database.
* Patent applied
Candidate formula selection and fine color matching
● Less waste● Metallic impression theory applicable colors: 70% of all metallic colors
1 Achieves color matching throughmore accurate formulas
● When there is a limited data volume for the approximate color, all the data can be effectively used.
2 Provides a specific guide when a color is undecided
Comparison within the company
(8 to 10 minutes)
10 minutes 1 minute
approximately
1/10
Applicable range of themetallic impression theory70% of metallic and metallic pearl colors are supported
Time-saving in all-data searching
19 20
Preparation and issuance of MSDS have been
implemented since the enactment of three related laws
in 2000 and 2001.
The primary purpose of MSDS are to inform paint users
of the risk to people and the environment, in order to
prevent industrial accidents from occurring. Additionally,
this means the transfer and release quantities of PRTR
substances can be calculated from their composition
(substance name and contents).
Kansai Paint has established the following system to
provide users with our product MSDSs, which can be
automatically issued using the basic database. The
contents of such MSDSs have also been fine-tuned
to provide more accurate' and the latest information in
order to fully comply with laws and regulations, because
we feel that MSDS is an important risk communication
tool for users. A MSDS that was updated up until the
previous day can also be searched by using the Kansai
Paint Group internal network system. Our distributors
can also use EDI system to provide a specific MSDS
to their users in a timely matter by searching and
downloading the MSDS.
List of Certified Kansai Paint Group Business Establishments in Japan and Overseas
5 Environmental Management System (ISO14001)
At Kansai Paint Co., Ltd., five plants, Tokyo Office,
R&D Center, and the Head Office all have individual
ISO14001 certification, and each plant and office is
conducting voluntary activities based on company-wide
environmental policies and targets.
In 2003, one affiliated company in Japan newly obtained
its ISO certificate. Kansai Paint continues to encourage
other affiliated companies to obtain such certification,
in order that we can strengthen environmental
management for the entire Kansai Paint Group.
Kansai Resin (Thailand) Co., Ltd.
Registered in 2001
Thai Kansai Paint Co., Ltd.Registered in
2002
Kanuma PlantRegistered in
1998
Hiratsuka PlantRegistered in
1999
Ono PlantRegistered in
2000
Amagasaki PlantRegistered in
2000
Nagoya PlantRegistered in
2000
Head OfficeRegistered in
2001
Tokyo Technical & Business Office
Registered in 2001
R&D CenterRegistered in
2002
Miyoshi Chemicals, Inc.Registered in
2001
Kuboko Paint Co., Ltd.Registered in
2002
Kanpe Hapio Co., Ltd.Registered in
2002
Nippon Kako Toryo Co., Ltd.Registered in
2004
Goodlass Nerolac Paints Ltd. (Lote plant)
Registered in 2002
Goodlass Nerolac Paints Ltd. (Kanpur plant)
Registered in 2003
Taiwan Kansai Paint Co., Ltd. Registered in
2000
Chongqing Kansai Paint Co., Ltd.
Registered in 2001
The Japan Chemical Industry Association established
the Yellow Card (emergency contact card) system as a
part of its Responsible Care activities, to quickly cope
with accidents that occur during the transportation of
chemical substances that are hazardous to humans and
the environment. When transporting a wide variety of
materials, however, a number of Yellow Cards need to be
carried in the vehicle, thus making it difficult to identify
specific substances in emergencies.
To complement the conventional Yellow Card system,
the Japan Chemical Industry Association established
the Container Yellow Card labeling system, which
requires that the index code of the Yellow Card and UN
numbers for the hazardous substances are noted on
the container label, facilitating rapid and appropriate
responses in emergencies.
Kansai Paint was quick to introduce this new labeling
system (see the figure below), and is working
continuously to ensure safety during transportation of
chemical substances.
Industrial Safety and Health Law April 2000
Pollutant Release and Transfer
Register (PRTR) LawJanuary 2001
Poisonous and Deleterious
Substances Control LawJanuary 2001
Obligation to issue MSDS
Purpose of MSDS
7. MSDS
4 Environmental Management
8. Container Yellow Card
Potential hazard
Public safety (protective equipment, evacuation)
Emergency actions (fire, leakage, first aid)
ID number
UN number
Container Yellow Card(labeling system)
Manufacturer
MSDS
Users
Understanding of the risk to the environment, safety, and health
Prevention of industrial accidents
Hazardous and toxic information
Product design(formula)
Product MSDS
Automaticpreparation
Customers,users
Clients
Business offices(or Distributors)
Raw materialselection
Risk assessment
Law materials' MSDS informationLiterature and law (enacted/revised) information
Basic database(laws and substances information)
ALESPEX
EDI system
Internal chemical substance control system
21 22
2. Energy Saving and the Prevention of Global Warming
6 Business Activities to Reduce the Environmental Burden
Change in energy consumption and source-distribution in the production division
Note
In environmental performance data, a value for
the same item name may differ depending on its
category, such as energy, waste, and environmental
accounting. This is as a result of dif fer ing
accounting methods in each category, as shown in
the table at right.
It is said that 95% of greenhouse gases emitted into
the atmosphere in Japan come from carbon dioxide
generated by energy consumption.
Although production quantities in FY2003 saw
only a slight increase of 0.4% over FY2002, energy
consumption decreased 4.6% in the same period, and
carbon dioxide atmospheric emissions also decreased
5.1% from FY2002.
At the Hiratsuka Plant, carbon dioxide atmospheric
emissions were reduced by 9% from FY2002 as a result
of promoting heat insulation paint on the roof, installing
upgraded air-conditioning systems, and improving steam
piping systems.
As a measure against global warming, Kansai Paint aims
to make effective use of different energies: therefore,
the company has invested in introducing co-generation,
replacing machinery that runs on fuel with that which
runs on the city gas, conducted energy-saving activities
for round-the-clock manufacturing facilities, and used
inverter controls for a reduced number of motored
appliances. Furthermore, whenever a air-conditioning
system is replaced, it is done so using one that uses
refrigerant that has less greenhouse effect, as well as
higher heat exchange efficiency.
We will strive to strengthen our energy-saving activities,
and to use recyclable energies such as photovoltaic and
wind power generation.
Title Breakdown
PlantContain production division and technical division within the same plant premises
Production divisionProduction division only within the plant premises
All companies 5 plants, R&D Center, Tokyo Office
CO2 emissions by plant (compared with FY2002)
CO2 emissions
0
10,000
20,000
30,000
40,000
50,000
60,000
'93'92 '94 '95 '96 '97 '98 '99 '00 '02 '03'01
(t・CO2) (kg・CO2/kg)
(FY)
0.00
0.05
0.10
0.15CO2 emissions (total amount)CO2 emissions (in basic unit)
CO2 emissions(total amount)
CO2 emissions(in basic units)
0
100
200
300
400
500
600
700
800
'93'92 '94 '95 '96 '97 '98 '99 '00 '02 '03'01
(109KJ)
(FY)
Energy used
Kerosene Heavy oil Gas Electricity
0
3,000
6,000
9,000
12,000
15,000FY2002
FY2003
Hiratsukaplant
Amagasakiplant
Nagoyaplant
Kanumaplant
Onoplant
(t・CO2)
1. Environmental Material Balance
6 Business Activities to Reduce the Environmental Burden
The shortage of final disposal sites for waste has
become an acute social problem, therefore the formation
of a recycling-oriented society has been an important
issue for manufacturers.
Kansai Paint is promoting 3R (Reduce waste emissions,
Reuse, and Recycle) in order to create such a
recycling-oriented society, and to decrease risks to the
environment.
Table 1 explains the material flow items in our
business activities, and Table 2 shows a comparison
of input resources and energy, with emissions to the
environment.
Raw materials Amount of raw materials used to manufacture products (excluding containers, packaging materials, and fuels).
Recycled amount Amount of manufacturing wastes that were recycled.
Energy input (electricity) Amount of electrical energy purchased for manufacturing (excluding amount used for technical activities).
Energy input (liquid fuels)Amount of fuel used for manufacturing (excluding amount used for technical activities.) Heat recovery through thermalrecycling is not included.
Water resource input Total amount of water used.
Emissions of greenhouse effect gases and others (CO2 emissions)
Amount of CO2 emitted from manufacturing activities.
Ditto (SOx emissions) Amount of atmospheric emissions from smoke and soot generating facilities.
Ditto (NOx emissions) Amount of atmospheric emissions from smoke and soot generating facilities.
Emission of waste, etc. Amount of waste, etc. generated from manufacturing processes, excluding wastewater.
Final disposal amount Amount of waste for contracted disposal, incineration, and/or final landfill.
Wastewater amount Amount of processed wastewater generated from manufacturing activities.
INPUT
Item FY2003Over prev.
year
Material input
Raw materials (t) 252,000 (+8%)
Recycled amount (t) 28,000 (+11%)
Energy input
Electricity (GJ) 420,000 (-2%)
Gas (GJ) 150,000 (-10%)
Liquid fuel (heavy oil,
kerosene) (GJ)100,000 (-6%)
Water resource input
Water usage (m3) 647,000 (-8%)
OUTPUT
Item FY2003Over prev.
year
Greenhouse effect gas emissions
CO2 emissions (t・CO2) 31,000 -5%
SOx emissions (t) 1,500 -6%
NOx emissions (t) 12,000 +-0%
Emission of waste, etc., final disposal amount
Waste emissions (t) 29,000 +7%
Final disposal amount (t) 1,200 -45%
Wastewater
Processed wastewater (t) 13,700 -26%
Table 1 Items in Material flows
Table 2 Material balance
Manufacturing volumes were slightly increased by 0.4%
from FY2002; however, streamlining the manufacturing
processes reduced energy input in all categories of
electricity, gas, and liquid fuels. Total energy input
was reduced by 5% from the previous year, and CO2
emissions quantities were also reduced by 5% from
FY2002.
Waste amounts increased from FY2002. However,
recycled material usage increased to 28,000 tons, 11%
up from FY2002, as resulting from of recycling waste
paint and solvents. The amount of final landfilled waste
via external disposal companies decreased a substantial
45% from FY2002.
We will continue to recycle, and to reduce waste
quantities, in order to contribute to a recycling-oriented
society.
Manufacturingactivities
by Kansai Paint
Change in CO2 emissions in the production division -Total amount & amount per basic unit-
23 24
The annual water resource used in FY2003 was
658,000 m3, 42,000 m3 less from FY2002. Although
the production volume of paint and synthetic resin
increased slightly by 0.4% from FY2002, water usage
was decreased by 7.5% as a result of water saving
activities.
The Amagasak i P lant had the highest water
consumption among the five plants in FY2002. The
plant invested in water-saving measures such as
modification to eliminate main pipe leakage for water
supply and industrial water, and it also attempted the
effective usage of cooling water in synthetic resin and
paint manufacturing processes.
Employees are also asked to reduce water usage in
cafeterias and bathrooms and so on. These efforts have
resulted a 20% reduction in water consumption from
FY2002.
4. Waste Reduction (Reduce, Recycle, Reuse)
6 Business Activities to Reduce the Environmental Burden
Kansai Paint's five plants generate waste through the
production of paint and other products. In response
to this, Kansai Paint is promoting Reduction in waste
generation, Recycling, and Reuse of wastes aimed at
creating a recycling-oriented society.
In FY2003, we have promoted reducing the amount of
waste paints and solvents, which account for a majority
of the company waste. Eco Systems Co., Ltd., which is a
Kansai's subsidiary located within our Amagasaki plant
and possesses waste paint/solvent recycling facilities
developed by Kansai Paint, processed increasing
amounts of waste, and produced a great deal of recycled
material. As a result, there was an 87% increase over
FY2002 in the amount of contracted recycled waste.
The final disposal amount generated from the production
division that was contracted to external disposal
companies showed a dramatic 45% reduction from
FY2002. The ratio of waste recycled reached 96%,
surpassing the target of 95%.
(FY)
0
10,000
20,000
30,000
40,000
'99 '00 '01 '02 '03
(t)Waste amount
(FY)
0
10,000
20,000
30,000
40,000
'99 '00 '01 '02 '03
(t) (t)
Recycled amountContracted finaldisposal amount
0
2,000
4,000
6,000
8,000Recycled amount
Contracted final disposal amount
Change in waste generation, recycled amount, and final disposal amount
Breakdown of wastes
3. Measures to Reduce Water Resource Input
6 Business Activities to Reduce the Environmental Burden
Water resources are used in various ways, such as a raw
material for water-borne paint, processing water used
as cooling water, washing water, heat media (steam) or
other ways in manufacturing processes, and as human-
use water, used for drinking, in bathrooms, in toilets and
so on.
Main usage of water resources
Water as raw material
Processing water
Human-use water
Water to be used for water-borne varnish and paint
Washing water for water-borne paint manufacturing facilities, hot steam as heat media, and cooling water
Cafeteria, drinking water, bathroom water, toilet water
0
50
100
150
200
250(1000m3)
FY2002FY2003
Nagoyaplant
Hiratsukaplant
Amagasakiplant
Kanumaplant
Onoplant
Change in water consumption throughout the entire company
Change in water consumption by plant
Water consumption
Basic units(FY)
0
200
400
600
800
1,000
'99'98 '00 '01 '02 '03
(1000m3)
0
1
2
3
4
5
(FY)
(L/kg)
'99'98 '00 '01 '02 '03
( )The values in parentheses are for FY2002
Recycling ratio (%) = x 100(Internally recycled amount + Externally recycled amount)
Total waste
96% (92%)
Recycling ratio
29,400 tons (27,600 tons)
Total amount of waste (excluding waste water)
Contracted final disposal amountExternally recycledInternally recycled
Amount internally reused, recycled,
or re-circulated, such as heat
recovery within plants.
Amount sold externally, or externally
recycled and used.
Amount of waste for contracted disposal,
incineration, and/or final landfill.
1,200 tons (2,200 tons)7,300 tons (3,900 tons)20,900 tons (21,500 tons)
25 26
Raw material candidates
Product design
Registered materials?
Any restrictions on use?
New materials
-Investigation
-MSDS, etc.
Dangerous or harmful materials?
Cautioned materials?
Prohibited materials?
Prohibited materials
Cautioned materials
Ordinary and common materials
Dangerous or harmful materials
Corporate rules
Evaluation and judgement
Design work
Registration
Review and re-design
��
��
��
��
��
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���
���
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1
2
3
4
1
2
3
3) Reduction of Hazardous Substances
We have reduced another 1%, achieving a total 99%
reduction. We aim to totally abolish usage of these
substances by the end of FY2004.
Target materials
(t/year)0 5,000 10,000 15,000 20,000 25,000
(FY)
'99
'00
'01
'02
'03
'04
'05
'06 (Target)
(Estimated)
(t/year)0 2 4 6 8 10 12
(FY)
'01
'02
'03
'04
'05 (Target)(t/year)
0 100 200 300 400 500 600 700
(FY)
'99
'00
'01
'02
'03
'04
'05 (Target)
(t/year)0 100 200 300 400 500 600 700
(FY)
'98
'97
'96
'95
'99
'00
'01
'02
'03
'04
'05
5. Management of Chemical Substances
6 Business Activities to Reduce the Environmental Burden
For 1st stage reduction Related PRTR Law No.
Dichloromethane (1ー145)
1,4-Dioxane (1ー113)
Ethyleneglycol monoethylether (1ー 44)
Ethyleneglycol monoethylether acetate (1ー101)
Ethyleneglycol monomethylether (1ー 45)
Ethyleneglycol monomethylether acetate (1ー103)
Tri-alkyl tin compounds (1ー176)
For 2nd stage reduction Related PRTR Law No.
Chromium (VI) compound (1ー 69)
Lead compound (1ー230)
For 3rd stage reduction Related PRTR Law No.
Xylene (1ー 63)
Toluene (1ー227)
Ethylbenzene (1ー 40)
For 4th stage reduction Related PRTR Law No.
Polyoxyethylene nonyl phenyl ether (1ー 309)
Raw materials are divided into 4 groups according to
their hazardous and harmful characteristics as follows.
The main information sources are domestic and
international rules and regulations.
Classes Corporate rules
1 Prohibited materials Prohibited to use
2 Dangerous or harmful materials Limited use (on registration)
3 Cautioned materialsAllowed to use with care (on registration)
4 Ordinary and common materials Normal use
2)Our Classification
To reduce the environmental burden of our products
(paints), hazardous substances are selected as shown
in the table, and a reduction plan for each substance is
established and promoted.
1st stage reduction substances
2nd stage reduction substances
3rd stage reduction substances
4th stage reduction substances
The usage of hexavalent chromium has been gradually
decreasing, however, the rate of the reduction has been
slowing, partially because it takes time to verify long-
term weathering performance. However, our efforts in
reduction continue.
Raw materials containing hexavalent chromium
Change in purchased amount of raw materials containing hexavalent chromium
Lead containing raw materials (excluding hexavalent chromium containing materials)Usage of lead compounds has been gradually
decreasing, meeting the target reduction rate. Our
efforts in reduction continue.
Usage is decreasing, but not at a fast enough pace.
Aromatic solvents are considered to contribute towards
air pollution, and we will continue our efforts to meet
targets through the promotion of water-borne coatings
for automobiles, and so on.
Change in purchased amount of xylene and toluene solvents
A target for reducing total VOC emissions is under
consideration, in response to a newly instituted law.
This is progressing as scheduled.
Amount of polyoxyethylene nonyl phenyl ether used
1) Corporate Rules regarding Selection of Raw Material at the Product Design Stage
(t/year)0 300 600 900 1200
(FY)
'99
'00
'01
'02
'03
'04
'05 (Target)
Kansai Paint has consistently strived
to reduce and eliminate the use of
hazardous chemical substances, both
in products and in manufacturing
processes. For this purpose, we have
set a standard evaluation system as
illustrated at right, that enables the
elimination of hazardous materials at
the product design stage.
27 28
(FY)
Butyl alcoholToluene Ethylbenzene Ethyl acetateXylene
0
50
100
150
200
'98'97 '99 '00 '01 '02 '03
(t)
Atmosphericrelease
0
5,000
10,000
15,000
20,000
'98'97 '99 '00 '01 '02 '03
(t)
(FY)
Usage
Designated substances
6. PRTR Substances' Release and Transfer
6 Business Activities to Reduce the Environmental Burden
1) FY2003 Release and Transfer Quantity
Data has been collected since January 2001 for the
PRTR substances stated on the raw material MSDS.
The number of substance to be registered with the
government was increased to 54 items in 2004
(FY2003 targeted), up from 17 in 2003, because
the annual criteria volume of class-1 designated
chemical substances was modified to five tons in 2004
(calculated from FY2003), from previous requirements
of one ton; however, the total volume was decreased by
3% from FY2002.
The number of substances defined by the Japan
Chemical Industry Association (JCIA) increased to
24 items (excluding those required by the law), from
the previous 23 items, and their total quantities were
slightly decreased from FY2002.
In addition to the substances defined by the law,
substances defined by JCIA are also assessed. The
top 10 substances covered by the PRTR and JCIA in
terms of volume are listed below, to provide atmospheric
release and transfer data.
7. Life Cycle Assessment (LCA) Initiatives
6 Business Activities to Reduce the Environmental Burden
We have been studying the life cycle assessment of
paint to provide quantitative environmental burden data,
and to help designing environment-friendly paints and
their application process. Examples of LCA evaluations
on a synthetic resin production and water-borne base
coat for automobile topcoat are shown below.
Using recycled PET is connected with reduction of
waste PET in society, and reduces by 10% carbon
dioxide emission from coating resin production,
including from raw material mining processes, when
compared with conventional production processes.
The amount of carbon dioxide generated from water-
borne base coats production is 90% of that from
solvent-based base coats, proving that water-
borne base coats impose a lighter burden on the
environment.
Comparison of resins using recycled PET
Performing LCA evaluation for paints provides an
effective tool to quantitatively understand the paints'
burden on the environment. We will continue this study
to assist the development of new products with reduced
burden on the environment.
3.0
2.0
1.0
0
(kg・CO2/kg)
Recycled PET usedRecycled PET not used
Environmental burden (CO2 emission)
2.0
1.5
1.0
0.5
0
(kg・CO2/kg)Environmental burden (CO2 emission)
water-bornebase coats
solvent-basedbase coats
Example 2
Example 1
8. Eco-Product Ratio
By developing and offering products that are kind on
both people and the environment, Kansai Paint has
ensured that environment-friendly products (eco-
products) will account for 60% of our product sales in
FY2005. Evaluation items and details are specified for
each eco-product.
In FY2003, eco-products met the target of comprising
48% of our sales volume. Among the eco-products sold
in FY2003, 70% comprised paint with reduced VOC
content, such as water-borne paints.
We continue to develop and expand sales of eco-
products in order to increasingly provide environment-
friendly products that are designed for better human
health, and for the protection of the environment.
100
80
60
40
20
0'02 '03 '04 '05 (FY)
(%)
ALES ECO PLAN2005 target
PRTR No. Substance name Atmospheric
release (kg)
Quantity motransferred
(kg)
2 Acrylamide 0 1
3 Acrylic acid 0 18
4 Ethyl acrylate 0 27
6 Methyl acrylate 0 3
7 Acrylonitrile 0 1
13 2,2'-azobisisobutyronitrile 0 17
16 2-Aminoethano 0 16
24 n-alkylbenzenesulfonic acid and it's salt 0 64
25 Antimony and its compounds 0 170
27 Isophorome diisocyanate 0 8
29 Bisphenol A 0 90
30 Bisphenol A type epoxy resin (liquid type) 0 30507
40 Ethylbenzene 43300 136500
43 Ethylene glycol 3 2913
44 Ethylene glycol monoethyl ether 1 41
63 Xylene 52000 163900
67 Cresol 8 23
68 Chromium and chromium(III) compound 0 73
69 Chromium (VI) compound 0 734
100 Cobalt and its compounds 0 63
101 Ethylene glycol monoethyl ether acetate 2 38
102 Vinyl acetate 0 1
129 3-(3,4-Dichlorophenyl)-1,1-dimethylurea 0 32
160 2-(Di-n-butylamino)ethanol 14 21
176 Organic tin compounds 1 1181
177 Styrene 0 58
179 Dioxins (mg-TEQ) 1 5.0×10-4
205 Terephthalic acid 0 17
224 1,3,5-Trimethylbenzene 3340 10331
227 Toluene 71100 131500
230 Lead and its compounds 2 6450
231 Nickel 0 44
232 Nickel compounds 0 45
242 Nonylphenol 0 19
266 Phenol 11 37
270 Dibutyl phthalate 0 708
272 Bis(2-ethylhexyl) phthalate 0 666
273 Butyl benzyl phthalate 0 50
293 Hexamethylene diisocyanate 235 37
300 1,2,4-Benzenetricarboxylic 1,2-anhydride 0 84
308 Poly(oxyethylene) octylphenyl ether 0 800
309 Poly(oxyethylene) nonylphenyl ether 0 60
310 Formaldehyde 591 539
312 Phthalic anhydride 0 310
313 Maleic anhydride 0 5
314 Methacrylic acid 0 155
315 2-Ethylhexyl methacrylate 0 117
316 2,3-Epoxypropyl methacrylate 0 527
318 2-(Dimethylamino)ethyl methacrylate 0 7
319 Butyl methacrylate 0 491
320 Methyl methacrylate 0 797
338 m-Tolylenediisocyanate 8 7
341 Methylenebis(4,1-cyclohexylene) diisocyanate 0 0
346 Molybdenum and its compounds 0 21
-- Ethyl acetate 34600 56160
-- Butyl alcohol 30900 88600
-- Butyl acetate 21500 44510
-- Methyl butyl ketone 20760 26540
-- Propyl alcohol 11931 30546
-- Methyl ethyl ketone 11240 17140
-- Methyl alcohol 5230 9780
-- Cyclohexanol 3990 9280
-- Butyl cellosolve 2603 27817
-- Acetone 2109 3830
Substances excluding PRTR substances (JCIA top 10 substances)
2) Annual Change in Usage, and Release of Major Chemicals
A total of all production division sites
Five substances that had the most significant
atmospheric release were selected from among RPTR
and JCIA substances, and their usage and amounts of
atmospheric release were plotted in the graphs. The top
five substances in terms of quantities released into the
atmosphere were unchanged from those of FY2002.
The amount of atmospheric release has been decreasing
for all substances.
* Methods for calculating atmospheric release quantitiesBased upon release calculation methods for manufacturing processes in the JPMA (Japan Paint Manufacturers Association) PRTR manual (published March 2001)
Comparison of basecoats of automobile topcoats
29 30
Safety and Health Activities
7 Social Efforts
Workplace Accidents FY2002 FY2003
Lost-work injuries 1 1
Minor injuries 5 8
1) Safety Activities and Results
There were several large-scale accidents experienced
by large-scale corporations in FY2003, and these
accidents remind us that safety must be a top priority
item in our business activities. Furthermore, Kansai
Paint is aggressively implementing safety measures
throughout the company, aiming at our target of zero-
accidents.19th in-house seminar (Tokyo Office)
Various hazard prediction training is carried out to enhance awareness of hazards, and to prevent industrial accidents.
Annual change in accidents at work
Change in severity
FY2003 had as its target zero accidents, including
zero minor injuries, however there was an increase in
the number of minor injuries over FY2002. We will make
further efforts to better manage workplace safety and
training programs in order to prevent recurrences of
such accidents.
There was not a significant disparity in either the
frequency of accidents, or their severity between
FY2002 and FY2003. In FY2004, our target is to
achieve zero accidents, through the partial modification of
an occupational safety and health management system.
Annual change in frequency ratios for accidents
Frequency ratio for accidents =
Lost-work accidents (number of victims)/ Total man-hour x 1,000,000
JPMA: Frequency ratio for Japan Paint Manufacturers Association members
JCIA: Frequency ratio for Japan Chemical Industry Association members
0
5
10
15
20
25
(FY)
(Number of industrial accidents)
Lost-work injurieMinor injuries
'99'98'97'96'95'94'93'92'91'90 '00 '01 '02 '03
○ Annual Safety Check (July 1)
○ Safety & Health Inspection by Management:
5 plants, 1 Office, 4 Affiliates (September -
October)
○ In-house leaders training in hazard & accident
prevention workshop: West Japan (May), East
Japan (February), 40 attendees each.
○ Dispatched 20 persons/yr to external training
in hazard & accident prevention to foster expert
leaders
○ Safety News (17 times)
Main activities
Results (All plants and offices)
0.0
0.1
0.2
0.3
0.4
(FY)
(Severity)
JPMAKansai Paint
JCIA
'99'98'97'96'95'94'93'92'91'90 '00 '01 '02 '030
1
2
3
4
(FY)
(Frequency ratio)
JPMAKansai Paint
JCIA
'99'98'97'96'95'94'93'92'91'90 '00 '01 '02 '03
2) Safety Inspections for Affiliated Companies
An annual Safety & Health Inspection by management
is carried out for four affiliated companies in Japan. In
this, approximately ten people form a special inspection
team led by the general manager of the production
division, and this evaluates safety, health, environment,
disaster prevention training, etc. This has seen an overall
improvement every year. In the future, we plan to further
raise levels of safety at Kansai Paint Group companies,
through close communication with personnel regarding
safety and environmental preservation at group
companies.
Safety measures for affiliated companies in Japan
Safety measures for overseas affiliated companies Our overseas affiliated companies engage in paint
production and sales in China, Thailand, Malaysia,
Singapore, Indonesia, and India. Our aim is to work with
safety, health, and environmental issues globally, and we
have made progress in performing safety inspections for
six companies in China in FY2003.
Before the commencement of local inspections, local
Japanese staff conducted self-assessment and
extracted important points for evaluation.
Inspection reports indicated that safety and health
seminars ensured overseas employees raised their
awareness as regards safety, and that they acquired
good understanding of electrostatic measures through
training.
Basic education regarding safety, environmental conservation, and pollution control are provided.
Safety inspection at Chongquing Kansai Paint Co., Ltd.
Safety inspection at Shenyang Kansai Paint Co., Ltd.
Training on electrostatic measures at Hunan Kansai Automotive Coatings Co., Ltd.
Regional education and training
Examples of industrial accidents such as pinching and entangling are shown, and safety measures are presented.
Education stressing the importance of electrostatic measures are provided using visual media.
1) Safety inspection using an overseas safety check list
Regional checking and training
In FY2003, safety inspections were conducted for
affiliated companies both in Japan and overseas.
Severity = Lost-work days / Total man-hour x 1,000
JPMA: Severity of accidents for Japan Paint Manufacturers Association members
JCIA: Severity of accidents for Japan Chemical Industry Association members
1) Safety, health, and environmental management
2) Safety measures
3) Electrostatic measures
○ Maintenance and compliance with rules and
regulations
○ Workplace environment
○ Inspection and training of electrostatic measures
○ Control and handling of chemical substances
2) Important inspection items
Environmental Report 2004 -Environment, Health & Safety- (3nd Issue) Published by KANSAI PAINT CO., LTD. Published, September 2004Planning & Editing, Product Quality & Environment Division Production, Business Planning &Administration DivisionUnauthorized reproduction of the contents of this publication is prohibited.
CorporateRegister.com 22/02/2006