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Case Study: Life Cycle Assessment Of Plastic Shoe Rack ... · Of Plastic Shoe Rack Using Injection...

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Case Study: Life Cycle Assessment Of Plastic Shoe Rack Using Injection Molding Machine SHARAH YUNIHAR SAPUTRA, DR. JESSICA HANAFI UNIVERSITAS PELITA HARAPAN Presented at Workshop on Life Cycle Assessment Research in Indonesia, Puspiptek-Serpong, 24-25 November 2015. Available in http://www.ilcan.or.id Copyright @ the respective author(s).
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Page 1: Case Study: Life Cycle Assessment Of Plastic Shoe Rack ... · Of Plastic Shoe Rack Using Injection Molding Machine ... Studying the LCA of plastic products that has a ... Polypropylene

Case Study: Life Cycle Assessment Of Plastic Shoe Rack Using Injection Molding Machine SHARAH YUNIHAR SAPUTRA, DR. JESSICA HANAFI

UNIVERSITAS PELITA HARAPAN

Presented at Workshop on Life Cycle Assessment Research in Indonesia, Puspiptek-Serpong, 24-25 November 2015. Available in http://www.ilcan.or.id Copyright @ the respective author(s).

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Background •Plastic industries in Indonesia is one of the most popular industry that is used by businessmen as their investments.

•According to the data issued by the ministry of industries in Indonesia in 2013, there are more than 890 plastic industry in Indonesia.

•It is supported by the high levels of consumption of plastics, up to 1.9 million tons (2013)

•Plastics take a long time to decompose naturally at the end of its life cycle. This can affect the environment.

•Not all plastics are biodegradable, for instance the plastics used in non packaging plastics.

•The effects of plastics may not appear at the end of its life cycle alone, but also from other parts of its life cycle.

Presented at Workshop on Life Cycle Assessment Research in Indonesia, Puspiptek-Serpong, 24-25 November 2015. Available in http://www.ilcan.or.id Copyright @ the respective author(s).

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Research Method LCA Method

LCA Method

Source: US EPA

Presented at Workshop on Life Cycle Assessment Research in Indonesia, Puspiptek-Serpong, 24-25 November 2015. Available in http://www.ilcan.or.id Copyright @ the respective author(s).

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Phase 1 of LCA: Goal Definition and Scope

Goal: Studying the LCA of plastic products that has a high level of production and consumption, with examples

taken from productions by the means of injection molding.

Scope: Case study of plastic shoe rack with a weight of 1.24 kg each and is mainly constructed from

Polypropylene that is produced by Union Plastik company. The company was established 30 years ago and has

a production facility in Kapuk, North Jakarta.

Presented at Workshop on Life Cycle Assessment Research in Indonesia, Puspiptek-Serpong, 24-25 November 2015. Available in http://www.ilcan.or.id Copyright @ the respective author(s).

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Data Collection Assessed Product: Plastic Shoe Rack

Presented at Workshop on Life Cycle Assessment Research in Indonesia, Puspiptek-Serpong, 24-25 November 2015. Available in http://www.ilcan.or.id Copyright @ the respective author(s).

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Product Structure Tree

Presented at Workshop on Life Cycle Assessment Research in Indonesia, Puspiptek-Serpong, 24-25 November 2015. Available in http://www.ilcan.or.id Copyright @ the respective author(s).

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Production Processes

Mixing Molding Inspection

& Scrap cleaning

Assembly Packaging

Crushing

Yes

No

Presented at Workshop on Life Cycle Assessment Research in Indonesia, Puspiptek-Serpong, 24-25 November 2015. Available in http://www.ilcan.or.id Copyright @ the respective author(s).

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Molded Parts from Injection Molding Machines

Rack Shelf Rack Foot Pok-Dop

Presented at Workshop on Life Cycle Assessment Research in Indonesia, Puspiptek-Serpong, 24-25 November 2015. Available in http://www.ilcan.or.id Copyright @ the respective author(s).

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Phase 2 of LCA: Life Cycle Inventory

LCI of Rack Shelf (in 1 shift of Production = 8 hours)

Presented at Workshop on Life Cycle Assessment Research in Indonesia, Puspiptek-Serpong, 24-25 November 2015. Available in http://www.ilcan.or.id Copyright @ the respective author(s).

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Phase 2 of LCA: Life Cycle Inventory (Cont’d)

LCI of Rack Shelf (in functional unit = 1 kg)

Presented at Workshop on Life Cycle Assessment Research in Indonesia, Puspiptek-Serpong, 24-25 November 2015. Available in http://www.ilcan.or.id Copyright @ the respective author(s).

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Phase 2 of LCA: Life Cycle Inventory (Cont’d) •LCI of Rack Foot (in 1 shift of Production = 8 hours)

•LCI of Rack Foot (in functional unit = 1 kg)

Presented at Workshop on Life Cycle Assessment Research in Indonesia, Puspiptek-Serpong, 24-25 November 2015. Available in http://www.ilcan.or.id Copyright @ the respective author(s).

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Phase 2 of LCA: Life Cycle Inventory (Cont’d) •LCI of Pok-Dop (in 1 shift of Production = 8 hours)

•LCI of Pok-Dop (in functional unit = 1 kg)

Presented at Workshop on Life Cycle Assessment Research in Indonesia, Puspiptek-Serpong, 24-25 November 2015. Available in http://www.ilcan.or.id Copyright @ the respective author(s).

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Phase 2 of LCA: Life Cycle Inventory (Cont’d) •LCI of Crushing (3 shift)

•LCI of Crushing (in functional unit = 1 kg)

Presented at Workshop on Life Cycle Assessment Research in Indonesia, Puspiptek-Serpong, 24-25 November 2015. Available in http://www.ilcan.or.id Copyright @ the respective author(s).

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Phase 3 of LCA: Life Cycle Impact Assessment

Network diagram of Plastic Shoe Rack’s Life Cycle, result from SimaPro LCIA calculation using ReCiPe Endpoint Method

Rack Shelf Rack Foot Pok-Dop

Shoe Rack

LC Shoe Rack

Presented at Workshop on Life Cycle Assessment Research in Indonesia, Puspiptek-Serpong, 24-25 November 2015. Available in http://www.ilcan.or.id Copyright @ the respective author(s).

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Phase 3 of LCA: Life Cycle Impact Assessment (Cont’d)

Midpoint:

IPCC

TRACI

CML-IA BASELINE

ReCiPe Midpoint

Endpoint:

ReCiPe Endpoint

Presented at Workshop on Life Cycle Assessment Research in Indonesia, Puspiptek-Serpong, 24-25 November 2015. Available in http://www.ilcan.or.id Copyright @ the respective author(s).

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Phase 3 of LCA: Life Cycle Impact Assessment (Cont’d)

GWP value = 7.45 kg CO2 eq

IPCC Method

Rack Shelf Rack Foot Pok-Dop

Presented at Workshop on Life Cycle Assessment Research in Indonesia, Puspiptek-Serpong, 24-25 November 2015. Available in http://www.ilcan.or.id Copyright @ the respective author(s).

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Phase 3 of LCA: Life Cycle Impact Assessment (Cont’d) IPCC Method – Process Contribution

Process Unit Total Rack Shelf Rack Foot Pok-Dop Printed

paper

Packaging

film, PE Transport

Disposal

Product

Total for All

Processes kg CO2 eq 7.45 5.83 1.14 0.40 0.00 0.02 0.01 0.05

Polypropylene,

granulate kg CO2 eq 5.31 4.24 0.89 0.17 0.00 0.00 0.00 0.00

Electricity, high

voltage kg CO2 eq 1.73 1.28 0.18 0.21 0.00 0.00 0.00 0.05

Toner, colour,

powder kg CO2 eq 0.38 0.31 0.06 0.01 0.00 0.00 0.00 0.00

Packaging film, PE kg CO2 eq 0.02 0.00 0.00 0.00 0.00 0.02 0.00 0.00

Transport kg CO2 eq 0.01 0.00 0.00 0.00 0.00 0.00 0.01 0.00

Printed paper kg CO2 eq 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

Injection Moulding

Nangrong kg CO2 eq 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

Injection

Moulding,

ISYM1600

kg CO2 eq 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

Injection

Moulding, CLF

250T

kg CO2 eq 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

Disposal Product kg CO2 eq 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

Crushing kg CO2 eq 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

Coloured PP kg CO2 eq 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

Presented at Workshop on Life Cycle Assessment Research in Indonesia, Puspiptek-Serpong, 24-25 November 2015. Available in http://www.ilcan.or.id Copyright @ the respective author(s).

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Phase 3 of LCA: Life Cycle Impact Assessment (Cont’d) TRACI Method

Rack Shelf Rack Foot Pok-Dop

Presented at Workshop on Life Cycle Assessment Research in Indonesia, Puspiptek-Serpong, 24-25 November 2015. Available in http://www.ilcan.or.id Copyright @ the respective author(s).

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Phase 3 of LCA: Life Cycle Impact Assessment (Cont’d) TRACI Method – Normalization Inventory

# Impact category Unit Total Rack Shelf Rack Foot Pok-Dop Printed

paper

Packaging film,

PE Transport

Disposal

Product

1 Carcinogenics 0.0126 0.0097 0.0018 0.0009 0.0000 0.0000 0.0000 0.0002

2 Ecotoxicity 0.0027 0.0021 0.0004 0.0002 0.0000 0.0000 0.0000 0.0000

3 Eutrophication 0.0016 0.0012 0.0002 0.0002 0.0000 0.0000 0.0000 0.0000

4 Non carcinogenics 0.0009 0.0007 0.0001 0.0001 0.0000 0.0000 0.0000 0.0000

5 Fossil fuel depletion 0.0009 0.0007 0.0001 0.0000 0.0000 0.0000 0.0000 0.0000

6 Respiratory effects 0.0004 0.0003 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000

7 Global warming 0.0003 0.0002 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000

8 Acidification 0.0002 0.0002 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000

9 Smog 0.0002 0.0002 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000

10 Ozone depletion 0.0001 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000

Presented at Workshop on Life Cycle Assessment Research in Indonesia, Puspiptek-Serpong, 24-25 November 2015. Available in http://www.ilcan.or.id Copyright @ the respective author(s).

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Phase 3 of LCA: Life Cycle Impact Assessment (Cont’d) CML-IA Baseline Method

Rack Shelf Rack Foot Pok-Dop

Presented at Workshop on Life Cycle Assessment Research in Indonesia, Puspiptek-Serpong, 24-25 November 2015. Available in http://www.ilcan.or.id Copyright @ the respective author(s).

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Phase 3 of LCA: Life Cycle Impact Assessment (Cont’d) CML-IA Baseline Method – Normalization Inventory

# Impact category Unit Total Rack Shelf Rack Foot Pok-Dop Printed paper Packaging

film, PE Transport

Disposal

Product

1 Marine aquatic ecotoxicity 3.68E-11 2.76E-11 4.35E-12 3.86E-12 2.03E-14 5.74E-14 2.33E-14 8.67E-13

2 Abiotic depletion (fossil fuels) 6.71E-12 5.30E-12 1.08E-12 2.78E-13 6.42E-16 1.80E-14 3.51E-15 1.97E-14

3 Fresh water aquatic ecotox. 2.98E-12 2.22E-12 3.42E-13 3.27E-13 1.03E-15 3.78E-15 1.87E-15 7.50E-14

4 Global warming (GWP100a) 1.46E-12 1.14E-12 2.24E-13 7.84E-14 3.08E-16 3.93E-15 1.44E-15 1.01E-14

5 Acidification 1.07E-12 8.32E-13 1.57E-13 6.82E-14 3.69E-16 3.07E-15 8.66E-16 1.09E-14

6 Eutrophication 7.97E-13 6.01E-13 9.73E-14 7.91E-14 2.88E-16 1.86E-15 4.46E-16 1.73E-14

7 Photochemical oxidation 1.90E-13 1.49E-13 2.92E-14 1.02E-14 5.54E-17 5.09E-16 1.52E-16 1.30E-15

8 Human toxicity 1.74E-13 1.31E-13 2.13E-14 1.72E-14 8.80E-17 3.75E-16 2.67E-16 3.75E-15

9 Terrestrial ecotoxicity 8.47E-14 6.45E-14 1.11E-14 7.15E-15 7.63E-17 2.18E-16 2.08E-16 1.43E-15

10 Abiotic depletion 1.33E-14 1.00E-14 1.97E-15 6.78E-16 3.44E-17 9.48E-17 4.22E-16 8.59E-17

11 Ozone layer depletion (ODP) 2.04E-15 1.53E-15 2.54E-16 1.90E-16 1.39E-18 4.67E-18 1.39E-17 4.06E-17

Presented at Workshop on Life Cycle Assessment Research in Indonesia, Puspiptek-Serpong, 24-25 November 2015. Available in http://www.ilcan.or.id Copyright @ the respective author(s).

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Phase 3 of LCA: Life Cycle Impact Assessment (Cont’d) ReCiPe Midpoint Method

Rack Shelf Rack Foot Pok-Dop

Presented at Workshop on Life Cycle Assessment Research in Indonesia, Puspiptek-Serpong, 24-25 November 2015. Available in http://www.ilcan.or.id Copyright @ the respective author(s).

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Phase 3 of LCA: Life Cycle Impact Assessment (Cont’d) ReCiPe Midpoint Method – Normalization Inventory

# Impact category Unit Total Rack Shelf Rack Foot Pok-Dop Printed paper Packaging

film, PE Transport

Disposal

Product

1 Fossil depletion 0.00318 0.0025 0.00051 0.00013 3.0E-07 8.5E-06 1.7E-06 9.4E-06

2 Climate change Human Health 0.00075 0.00059 0.00012 4.0E-05 1.6E-07 2.0E-06 7.4E-07 5.2E-06

3 Particulate matter formation 0.00075 0.00057 8.8E-05 8.2E-05 6.8E-08 5.1E-07 2.1E-07 1.9E-05

4 Human toxicity 8.6E-05 6.4E-05 9.8E-06 9.5E-06 2.7E-08 9.2E-08 9.0E-08 2.2E-06

5 Climate change Ecosystems 6.4E-05 5.0E-05 9.7E-06 3.4E-06 1.3E-08 1.7E-07 6.2E-08 4.4E-07

6 Metal depletion 9.7E-06 7.4E-06 1.4E-06 6.3E-07 1.8E-08 5.9E-08 1.2E-07 1.0E-07

7 Natural land transformation 7.2E-07 5.4E-07 8.8E-08 7.0E-08 3.7E-10 1.4E-09 4.7E-09 1.5E-08

8 Urban land occupation 4.3E-07 3.3E-07 6.6E-08 2.1E-08 4.4E-10 1.8E-09 5.4E-09 2.3E-09

9 Agricultural land occupation 3.3E-07 2.2E-07 4.3E-08 1.7E-08 2.1E-08 2.2E-08 1.4E-09 2.5E-09

10 Terrestrial acidification 1.7E-07 1.4E-07 2.5E-08 1.1E-08 5.9E-11 4.9E-10 1.5E-10 1.8E-09

11 Ionising radiation 1.6E-07 1.2E-07 2.2E-08 1.0E-08 3.4E-10 1.5E-09 6.8E-10 1.6E-09

12 Freshwater eutrophication 1.1E-07 8.5E-08 1.3E-08 1.3E-08 2.7E-11 9.5E-11 3.2E-11 2.9E-09

13 Photochemical oxidant

formation 8.2E-08 6.4E-08 1.3E-08 4.2E-09 1.5E-11 2.4E-10 7.4E-11 5.1E-10

14 Freshwater ecotoxicity 4.3E-08 3.2E-08 5.1E-09 4.5E-09 2.0E-11 7.6E-11 4.6E-11 1.0E-09

15 Terrestrial ecotoxicity 3.9E-08 3.0E-08 5.4E-09 2.9E-09 2.6E-11 1.0E-10 3.2E-10 5.3E-10

16 Ozone depletion 3.5E-08 2.6E-08 4.3E-09 3.2E-09 2.3E-11 7.4E-11 2.4E-10 6.9E-10

17 Marine ecotoxicity 8.4E-09 6.3E-09 9.9E-10 8.8E-10 3.7E-12 1.4E-11 1.1E-11 2.0E-10

Presented at Workshop on Life Cycle Assessment Research in Indonesia, Puspiptek-Serpong, 24-25 November 2015. Available in http://www.ilcan.or.id Copyright @ the respective author(s).

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Methods Election IP

CC

• Calculate only one category: GWP

• In other methods, GWP is not a significant impact category

TRA

CI • Carcinogenic

has a significant impact

• Carcinogenic has big enough difference in the normalization value with category #2 and #3

CM

L-IA

Ba

selin

e • Marine Aquatic Eco-toxicity has a significant impact

• Compare to TRACI, Marine Aquatic Eco-toxicity NOT has big enough difference in the normalization value with category #2 and #3

ReC

ipe • First three

categories show that they have significant impact

Presented at Workshop on Life Cycle Assessment Research in Indonesia, Puspiptek-Serpong, 24-25 November 2015. Available in http://www.ilcan.or.id Copyright @ the respective author(s).

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LCIA Analysis based on Chosen Methods

1. Fossil Depletion

2. Climate Change Human

Health

3. Particulate Matter

Formation

1. Carcinogenic

2. Eco-toxicity

3. Eutrophication

RECIPE MIDPOINT TRACI

Presented at Workshop on Life Cycle Assessment Research in Indonesia, Puspiptek-Serpong, 24-25 November 2015. Available in http://www.ilcan.or.id Copyright @ the respective author(s).

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Main substance: Oil Crude

(63.84% contribution)

Main substance: Chromium (VI)

compartment in Water (94.44%

contribution)

#1 FOSSIL DEPLETION #1 CARCINOGENIC

PP 91.13%

Electricity 6.35%

Other Processes 2.52%

PP 50.17%

Electricity 44.78%

Other Processes 5.05%

Presented at Workshop on Life Cycle Assessment Research in Indonesia, Puspiptek-Serpong, 24-25 November 2015. Available in http://www.ilcan.or.id Copyright @ the respective author(s).

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Main substance: CO2 (88.20%

contribution)

Main substance: Zink compartment in

water (35.93%), Antimony/Sb (16.26%)

dan Nickel (14.15%).

#2 CLIMATE CHANGE HUMAN HEALTH #2 ECO-TOXICITY

PP 68.72%

Electricity 25.56%

Other Processes 5.72%

PP 15.88%

Electricity 77.84%

Other Processes 6.28%

Presented at Workshop on Life Cycle Assessment Research in Indonesia, Puspiptek-Serpong, 24-25 November 2015. Available in http://www.ilcan.or.id Copyright @ the respective author(s).

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Main substance: Particulates, < 2.5

um released in air (71.22%

contribution)

Main substance: Phosphate (76.07%

contribution)

#3 PARTICULATE MATTER FORMATION #3 EUTROPHICATION

PP 1.04%

Electricity 97.58%

Other Processes 1.38%

PP 3.5%

Electricity 91.13%

Toner 4.59%

Other Processes 0.78%

Presented at Workshop on Life Cycle Assessment Research in Indonesia, Puspiptek-Serpong, 24-25 November 2015. Available in http://www.ilcan.or.id Copyright @ the respective author(s).

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Midpoint-to-Endpoint Relation

49.003% 48.987%

2.01%

Rack Shelf Rack Foot Pok-Dop

Presented at Workshop on Life Cycle Assessment Research in Indonesia, Puspiptek-Serpong, 24-25 November 2015. Available in http://www.ilcan.or.id Copyright @ the respective author(s).

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Midpoint-to-Endpoint Relation (Cont’d)

Resources

Fossil Depletion

PP Usage

Electricity Usage

Electricity is generated from

the combustion of crude oil,

and PP is made from the

crude oil

Presented at Workshop on Life Cycle Assessment Research in Indonesia, Puspiptek-Serpong, 24-25 November 2015. Available in http://www.ilcan.or.id Copyright @ the respective author(s).

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Midpoint-to-Endpoint Relation (Cont’d)

Human Health

Carcinogenic

Climate Change

Particulate Matter

Formation

Increase of diseases due to

the increase of Green

House Gas

Resource depletion

Respiratory disorders

Presented at Workshop on Life Cycle Assessment Research in Indonesia, Puspiptek-Serpong, 24-25 November 2015. Available in http://www.ilcan.or.id Copyright @ the respective author(s).

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Midpoint-to-Endpoint Relation (Cont’d)

Ecosystem

Eutrophication Eco-toxicity Damage of water

ecosystem

Lowering of water

quality

Unbalanced

ecosystem

Human Health

Presented at Workshop on Life Cycle Assessment Research in Indonesia, Puspiptek-Serpong, 24-25 November 2015. Available in http://www.ilcan.or.id Copyright @ the respective author(s).

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Phase 4 of LCA: Interpretation •Life cycle that uses the most material and energy is the process of shoe

rack production in manufacture using Injection Molding machine, with

rack shelf part which contribute the most.

•The life cycle of the shoe rack in midpoint causes a significant fossil

depletion, climate change-human health, particulate matter formation,

carcinogenic, eco-toxicity and eutrophication.

Presented at Workshop on Life Cycle Assessment Research in Indonesia, Puspiptek-Serpong, 24-25 November 2015. Available in http://www.ilcan.or.id Copyright @ the respective author(s).

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Phase 4 of LCA: Interpretation (Cont’d)

LCIA breakdown (Contribution > 50%):

•Crude oil (63.84%), Carbon Dioxide (88.20 %), Airborne Particulates < 2.5

um (71.22%), Chromium VI (94.44%), Phosphate (76.07%).

•Eco-toxicity: Zinc that is dissolved in water (35.93%), followed by

Antimony/Sb (16.26%) and Nickel (14.15%)

Significant effects come from the use of electricity and PP.

At the endpoint, the damage is significant towards resource and human

health.

Presented at Workshop on Life Cycle Assessment Research in Indonesia, Puspiptek-Serpong, 24-25 November 2015. Available in http://www.ilcan.or.id Copyright @ the respective author(s).

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Phase 4 of LCA: Interpretation (Cont’d)

Evaluation:

•The usage of renewable energy it is advisable to use energy saving

machines

•Combine the usage of PP with PET to make it more environmental

friendly.

•The usage of masks in the workspace.

Presented at Workshop on Life Cycle Assessment Research in Indonesia, Puspiptek-Serpong, 24-25 November 2015. Available in http://www.ilcan.or.id Copyright @ the respective author(s).

Page 36: Case Study: Life Cycle Assessment Of Plastic Shoe Rack ... · Of Plastic Shoe Rack Using Injection Molding Machine ... Studying the LCA of plastic products that has a ... Polypropylene

Thank you.

Presented at Workshop on Life Cycle Assessment Research in Indonesia, Puspiptek-Serpong, 24-25 November 2015. Available in http://www.ilcan.or.id Copyright @ the respective author(s).


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