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An environmentally An environmentally friendly iron?friendly iron?
TadejTadej MEZEKMEZEKMatejMatej IVARTNIKIVARTNIKAndrej POLJAKAndrej POLJAK
May 2005May 2005
Phase IPhase I
Describing the product and current material Describing the product and current material and energy needs !and energy needs !
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IntroductionIntroduction
There are about 700There are about 700 000 households (est.) in 000 households (est.) in Slovenia and about the same number of irons Slovenia and about the same number of irons (est. 1 iron/household).(est. 1 iron/household).
Ironing days are Saturday and Sunday and it Ironing days are Saturday and Sunday and it is mostly made by women (approx. 2h per is mostly made by women (approx. 2h per week week -- 3 family members).3 family members).
Average lifetime of iron is about 4 years.Average lifetime of iron is about 4 years.
New irons come with a oneNew irons come with a one--year warranty.year warranty.
Introduction (contIntroduction (cont’’d)d)
Our iron was made by Our iron was made by RowentaRowenta--elmaelma, about , about 15 years ago.15 years ago.
The iron consists of 32 different materials (117 The iron consists of 32 different materials (117 components) & weights 1components) & weights 1..369369 kg total and kg total and 11..155155 kg net.kg net.
Most of it is made out of steel, metals and Most of it is made out of steel, metals and many types of unlabeled plastic.many types of unlabeled plastic.
It is designed for 1000It is designed for 1000 W at 220W at 220 V.V.
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Disassembling the ironDisassembling the iron
Disassembly took us 45 Disassembly took us 45
minutes minutes
(3 persons)(3 persons)
Note: Note:
No professional No professional disassembly tools and disassembly tools and skillsskills
Iron measurementsIron measurements
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Disassembling the iron (contDisassembling the iron (cont’’d)d)Bellow you can see a picture of tiny little Bellow you can see a picture of tiny little parts and of the disassembly procedureparts and of the disassembly procedure
DisassemblyDisassembly--chart for ironchart for iron
1 369117TOTAL
164Fabric
610rubber (4 different types)
381aluminum
829wire (3 different types)
5114small metal pieces
3228metal screws
2514other steel
4942Steel - large piece
4514other plastics (7 different types)
13plastic type 07
41plastic type 06
151plastic type 05
121plastic type 04
701plastic type 03
1065plastic type 02 - bakelite
1583plastic type 01
2146box (package, carton) with instructions
Total weight (g)# piecesmaterial-component
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PackagingPackaging
15.6% of the total weight is packaging and 15.6% of the total weight is packaging and wrapping (cardboard insets, no plastic in wrapping (cardboard insets, no plastic in our model).our model).
Newer types of irons are packed in carton Newer types of irons are packed in carton boxes made of 90% recycled material.boxes made of 90% recycled material.
Recycling potentialRecycling potential
Most parts are metal and plastics and Most parts are metal and plastics and therefore offer significant recycling potential.therefore offer significant recycling potential.
Easy disassembly with proper toolsEasy disassembly with proper tools
No available data about precise percentage No available data about precise percentage of iron of iron recyclabilityrecyclability
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Recycling potential of different iron partsRecycling potential of different iron parts
RecyclableRecyclablePlastic (polypropylene, Plastic (polypropylene, polyester, polyester, acetalacetal resin, resin, polycarbonate)polycarbonate)Aluminum for soleplateAluminum for soleplateStainless steel for soleplate Stainless steel for soleplate sheetsheetSmall Small metal metal pieces (iron)pieces (iron)Cardboard and paperCardboard and paper
Not recyclableNot recyclableHeating element made of Heating element made of iron, iron, magnesitemagnesite and nickel and nickel copper wirecopper wireSilicone for different sealsSilicone for different seals
Cord connection and internal wires made of different raw materiaCord connection and internal wires made of different raw materials ls are recyclable in part.are recyclable in part.
Source - BSH Hišni aparati d.o.o. (Slovenian company which produce irons and other domestic electricalappliances for Bosch, Siemens, Ufesa and Gorenje)
MarketMarket
ExportExport--import data shows that there were import data shows that there were 33 163 irons exported from Slovenia (in a 33 163 irons exported from Slovenia (in a radius of about 1radius of about 1 000 km) and 161 650 irons 000 km) and 161 650 irons were imported from all around the globe were imported from all around the globe (yearly).(yearly).As we have some domestic producers, we As we have some domestic producers, we estimated an annual market to be close to estimated an annual market to be close to 200 000 irons sold per year (the same 200 000 irons sold per year (the same amount of old ones as well).amount of old ones as well).
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Materials savedMaterials savedTwo basic materials in our iron are steel and plastics. Two basic materials in our iron are steel and plastics. Packaging, too, is important (15.6% of total weight).Packaging, too, is important (15.6% of total weight).
If steel were 100% recycled, 129.8 tons of iron ore, 51.9 If steel were 100% recycled, 129.8 tons of iron ore, 51.9 tons of coal and 20.8 tons of limestone would be tons of coal and 20.8 tons of limestone would be saved annually.saved annually.
For the production of plastics, 164.4 tons of For the production of plastics, 164.4 tons of petroleum is used annually.petroleum is used annually.
If packaging were 90% recycled, 655 trees,If packaging were 90% recycled, 655 trees,
387 550387 550 kWh of electricity, 963 mkWh of electricity, 963 m33 of water and of water and 98.99 m98.99 m33 of oil would be saved annually.of oil would be saved annually.
- Numbers of irons sold in Slovenia every year (200 000)
Environmental impactsEnvironmental impacts
5252 780780 700700
11 344344 000000
284284 200200
55 213213 600600
33 444444 000000
11 975975 400400
1414 532532 000000
2727 331331 500500
Total energy Total energy required (MJ) required (MJ)
if from if from primary primary
source for iron source for iron in Sloveniain Slovenia
7575 401401
11 920920
406406
77 448448
44 920920
22 822822
2020 760760
3939 045045
Energy required Energy required (kJ) if from (kJ) if from
primary source for primary source for our given mass for our given mass for
one Ironone Iron
3737 047047
515515
406406
11 015015
33 690690
11 992992
99 394394
2020 550550
Energy Energy required (kJ) if required (kJ) if from recycled from recycled source for our source for our given mass for given mass for
one Ironone Iron
2525 932932 900900
360500360500
284200284200
710500710500
25830002583000
13944001394400
65758006575800
1414 385385 000000
Total energy Total energy required (MJ) if required (MJ) if from recycled from recycled
source for iron in source for iron in SloveniaSlovenia
11 155155
1616
66
3838
8282
8383
519519
411411
Total weight Total weight (g)(g)
TOTAL TOTAL
FabricFabric
Rubber (4 different types)Rubber (4 different types)
AluminumAluminum
Copper (wire)Copper (wire)
Other metal piecesOther metal pieces
Steel piecesSteel pieces
Plastics (various types)Plastics (various types)
materialmaterial--componentcomponent
Note: Cardboard and wrapping is omitted.
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Environmental impact and Environmental impact and energy production in Sloveniaenergy production in Slovenia
Thermoelectricity production in Slovenia accounts for 33%Thermoelectricity production in Slovenia accounts for 33%of the total electricity production, which means:of the total electricity production, which means:
13 kg of coal consumption per iron per household (3 persons) in 13 kg of coal consumption per iron per household (3 persons) in one yearone year14 kg of CO14 kg of CO22 emission per iron per household yearlyemission per iron per household yearly0.03 kg of SO0.03 kg of SO22 emission per iron per household in one year.emission per iron per household in one year.
Total of 9100 tons of coal consumption, 9Total of 9100 tons of coal consumption, 9 800 tons of CO800 tons of CO22 and 21 tons of SOand 21 tons of SO2 2 emissions due to iron use in Sloveniaemissions due to iron use in Slovenia!!
SourceSource-- Center of Energy and Environmental Technologies, Faculty of MecCenter of Energy and Environmental Technologies, Faculty of Mechanical Engineering, University hanical Engineering, University of Ljubljana, Sloveniaof Ljubljana, Slovenia
Environmental impactEnvironmental impactduring useduring use
One iron uses One iron uses 5050 kWhkWh of energy annually for of energy annually for domestic use in a household of 3 persons domestic use in a household of 3 persons (25 kWh for 1 person in household, 66 kWh for 4(25 kWh for 1 person in household, 66 kWh for 4persons in household).persons in household).
That means: That means: 126126 000000 000 MJ000 MJ of energy annually of energy annually for all ironing done in Slovenia .for all ironing done in Slovenia .
50 kWh*350 kWh*3 600600 s* 700s* 700 000 irons000 irons == 126126 000000 000000 MJ.MJ.
Source Source –– Center of Energy and Environmental Technologies, Faculty of MecCenter of Energy and Environmental Technologies, Faculty of Mechanical Engineering, University of Ljubljana,hanical Engineering, University of Ljubljana, SloveniaSlovenia
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Comparing energy usedComparing energy usedProduction phase:Production phase:
5252 780780 700 MJ (if no recycling)700 MJ (if no recycling)1313 195195 175 MJ per year 175 MJ per year
(considering lifetime of 4 (considering lifetime of 4 years)years)
1515 080080 200 MJ per year200 MJ per year
(considering 200(considering 200 000 sold 000 sold annually)annually)
1414 137137 687.5 MJ per year687.5 MJ per year(average)(average)
Use phase:Use phase:126 126 000000 000000 MJ per yearMJ per year
Energy used in production and use phase of iron
use production
ConclusionsConclusions
Irons are big energy consumers, and, comparing the Irons are big energy consumers, and, comparing the numbers for production and use, the redesign should numbers for production and use, the redesign should obviously be oriented toward the use phase, obviously be oriented toward the use phase, because almost 9 times more energy is used in that because almost 9 times more energy is used in that phase than in production.phase than in production.
Knowing that no energy conversion can achieve Knowing that no energy conversion can achieve 100% efficiency, a 10% improvement in energy 100% efficiency, a 10% improvement in energy conversion would save almost as much energy as conversion would save almost as much energy as whole production phase needs.whole production phase needs.
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Phase IIPhase II
Redesign Redesign ––
How to save on material and energy ?How to save on material and energy ?
IntroductionIntroduction
There is a large potential of energy savings in There is a large potential of energy savings in the use phase, but a 10% increase in efficiency the use phase, but a 10% increase in efficiency is much more than it seems and probably is much more than it seems and probably cannot be achieved. Still we tried to find ways cannot be achieved. Still we tried to find ways where the largest savings could be done where the largest savings could be done ––some quite unreasonable and others already some quite unreasonable and others already done.done.
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Redesigning the iron Redesigning the iron -- Redesign Redesign processprocess
11. ELIMINATE THE PROCESS . ELIMINATE THE PROCESS –– STOP IRONINGSTOP IRONING
Why is ironing needed? To smooth and disinfect Why is ironing needed? To smooth and disinfect the clothes. Nowthe clothes. Nowaadays clothes are washed so well days clothes are washed so well that there is no more disinfection needed and that there is no more disinfection needed and ironing has only an aesthetic function. It is also ironing has only an aesthetic function. It is also hard to say that ironing is free or fun time for hard to say that ironing is free or fun time for anybody.anybody.
DEEPDEEP…………………………..........……LYFESTILE CHANGELYFESTILE CHANGE
Redesigning the iron Redesigning the iron -- Redesign Redesign processprocess
2. CHANGE THE PROCESS 2. CHANGE THE PROCESS –– NEW TYPE OF NEW TYPE OF SMOOTHING DEVICESMOOTHING DEVICEWe could use an alternative smoothWe could use an alternative smoothinging process process like like ““ironingironing”” with blowing hot air on and inside with blowing hot air on and inside the clothes. It requires less time and effort to do the clothes. It requires less time and effort to do the same job.the same job.But is this alternative environmentally friendlier But is this alternative environmentally friendlier than the old ironing process?than the old ironing process?
DEEPDEEP…………………………………………DEVICE SUBSTITUTIONDEVICE SUBSTITUTION
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Redesigning the iron Redesigning the iron --Redesign processRedesign process
33. IMPROVE ENERGY CONVERSION MAKING IRONS. IMPROVE ENERGY CONVERSION MAKING IRONS
Change steel with better materials for heat Change steel with better materials for heat conduction and heat maintenance. It is actually conduction and heat maintenance. It is actually possible to use more material to save on overall possible to use more material to save on overall energy consumption (ex. cooking pots with energy consumption (ex. cooking pots with massive bottom) but would it work on irons?massive bottom) but would it work on irons?
SHALLOWSHALLOW………………PRODUCT CHANGE PRODUCT CHANGE
Redesigning the iron Redesigning the iron --Redesign processRedesign process
44. INTRODUCE IRONING SERVICES . INTRODUCE IRONING SERVICES –– REDUCE THE REDUCE THE NUMBER OF IRONSNUMBER OF IRONSLaundry services are well known already and after Laundry services are well known already and after washing they also iron your laundry washing they also iron your laundry –– good in principle good in principle but there is the transport issue. Possibility is also maid but there is the transport issue. Possibility is also maid ironing laundry for more clients with one iron at their ironing laundry for more clients with one iron at their home home –– service that comes to home. In buildings with service that comes to home. In buildings with more flats also laundry and ironing room for all the more flats also laundry and ironing room for all the residents could be organized.residents could be organized.
MODERATEMODERATE…………....………………DEMATERIALIZATIONDEMATERIALIZATION
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Redesigning the iron Redesigning the iron --Redesign processRedesign process
55. MAKE SOME COMPONENTS OF IRON . MAKE SOME COMPONENTS OF IRON EXCHANGEABLEEXCHANGEABLEIroning plates and water tanks could be produced Ironing plates and water tanks could be produced in ways that easy replacement would be possible, in ways that easy replacement would be possible, so when broken, only parts and not the whole iron so when broken, only parts and not the whole iron should be changed. Also, by using different plates, should be changed. Also, by using different plates, the process could be adjusted to the fabric being the process could be adjusted to the fabric being ironed and temperature used so energy would be ironed and temperature used so energy would be saved.saved.
DEEP/MODERATEDEEP/MODERATE…………....……REUSE/PRODUCT CHANGE REUSE/PRODUCT CHANGE
Redesigning the iron Redesigning the iron --Redesign processRedesign process
66. IMPROVE IRON ENERGY EFFICIENCY WITH . IMPROVE IRON ENERGY EFFICIENCY WITH HELP OF ELECTRONICSHELP OF ELECTRONICS
There are already There are already thermoregulatorsthermoregulators in irons for in irons for auto switch off when the desired temperature is auto switch off when the desired temperature is reached, but other improvements could also be reached, but other improvements could also be made: auto switch off when no contact with made: auto switch off when no contact with ironing table for 30 seconds, auto adjust ironing table for 30 seconds, auto adjust temperature to fabric.temperature to fabric.
MODERATEMODERATE………………PRODUCT CHANGE PRODUCT CHANGE
(IMPROVEMENT)(IMPROVEMENT)
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Redesigning the iron Redesigning the iron --Redesign processRedesign process
77. USE ONLY ONE TYPE OF SIMILAR . USE ONLY ONE TYPE OF SIMILAR MATERIAL MATERIAL
By using only one type of plastics, steel, By using only one type of plastics, steel, rubber etc., the product would gain on rubber etc., the product would gain on recycling potential.recycling potential.
SHALLOWSHALLOW…………………….....................RECYCLING.....................RECYCLING
Redesigning the iron Redesigning the iron --Redesign processRedesign process
88. MARK ALL MATERIALS IN IRON WITH . MARK ALL MATERIALS IN IRON WITH TYPICAL CODES TYPICAL CODES
The sorting by disassembly would go faster, The sorting by disassembly would go faster, and recyclable materials could be better and recyclable materials could be better recycled.recycled.
SHALLOWSHALLOW…….................DISASSEMBLY/RECYCLING.......DISASSEMBLY/RECYCLING
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ConclusionsConclusionsIrons and other electric appliances are part of Irons and other electric appliances are part of everyday life and need a lot of energy during there everyday life and need a lot of energy during there lifetime. So, life cycle analysis should be performed lifetime. So, life cycle analysis should be performed and production should probably focused on and production should probably focused on reducing energy needs in use phase. In longer lasting reducing energy needs in use phase. In longer lasting and continuously running appliances a lot on energy and continuously running appliances a lot on energy saving has already been done and some principles saving has already been done and some principles could be copied to irons. Of course the use of could be copied to irons. Of course the use of materials for greater recycling potential can also not materials for greater recycling potential can also not be forgotten.be forgotten.
Finally suggestionsFinally suggestionsSome tips that help conserve energy during Some tips that help conserve energy during ironing:ironing:
Plug on your iron only after you get all your clothes Plug on your iron only after you get all your clothes together.together.Sort your clothes by type of fabric. First you have to Sort your clothes by type of fabric. First you have to iron delicate clothes that need lower temperatures iron delicate clothes that need lower temperatures than clothes which need higher temperatures.than clothes which need higher temperatures.It is easier and faster to iron with steam type irons; It is easier and faster to iron with steam type irons; they save energy.they save energy.During longer breaks, switch off the iron.During longer breaks, switch off the iron.
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