Zero Waste Emissions Initiatives

Daio Paper strives for Zero Waste Emissions via the cyclical use of waste generated through the production of pulp and paper, for applications in cement materials, construction materials, land reclamation, and others.

Waste materials such as waste plastics discharged from the pulper and during the screening process of deinked pulp production are recycled into RPF*1, a type of fuel. Ink is removed from recovered paper using flotation equipment*2, and the residue froth*3 is recovered as inorganic chemicals (recycled filler) to be used in the papermaking process.

Mishima Plant Industrial Waste Disposal

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※1 RPF [Refuse Paper & Plastic Fuel]
Solid fuel made from non-reusable waste paper and waste plastics among industrial waste. Because of its high calorific value, it is used in many industries such as papermaking and steel as a substitute for fossil fuels such as coal and heavy oil.

※2 Flotation equipment
A device that washes and removes ink printed on recovered paper with chemicals (detergents) to release and reclaim paper fibers (pulp).

※3 Froth
Removed ink components and fine fibers and inorganic chemicals contained in the foam generated by the flotation equipment.

Recycling of Paper Resources

Daio Paper strives to reduce waste materials and conserve natural resources by making use of a filler recycling technology that it put to practical use ahead of other companies

In general, deinking sludge and inorganic chemicals that are removed as foreign matter during the production of deinked pulp are disposed of as waste. Daio Paper has put to practical use a technology to recycle the inorganic chemicals contained in this type of waste as fillers, and is currently using them in various types of paper, thereby reducing waste.

Our original companion recycling system

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Reducing the Amount of Incinerated Effluent Sludge Ash by Recycling Deinking Sludge into Filler

Deinking sludge, a waste product of deinked pulp production, used to end up as effluent sludge after treatment. However, at Daio Paper Mishima Mill, we are reusing deinking sludge by recycling it into filler (chemicals mixed into paper to achieve higher opacity).

Recycled filler production facilities

In order to reduce the amount of effluent sludge generated, we are working to improve the quality of recycled filler and expand the variety of paper we use recycled filler in.

Amount of incinerated sewage sludge ash reduced: about 24,000 tons. Recycled filler production facilities

To Improve the Quality of Recycled Fillers

1.Characteristics of high-grade recycled fillers

High-grade recycled filler is improved by coating the surface with particulate chemicals to makes it easier for oil to be absorbed into the interstices of the particles. When formulated into paper, it captures the oil of printing ink and prevents the oil from soaking through to the other side of the paper, reducing print strike-through (and print show-through) even for thin papers.

In addition, high-grade recycled filler contains a wide variety of minerals such as calcium carbonate and clay, which have different light scattering properties, and by controlling the particle size, it will also improve paper opacity.

Image of high-quality reclaimed filler
2. Benefits of incorporating into paper

By incorporating high-quality recycled filler into newsprint, it will improve paper opacity (reduce print strike-through) and paper flatness (improve ink receptivity), making it possible to reduce the weight of the paper.

Also, by coating the surface of the recycled filler, it reduces the roughness of the surface of the filler. As a result, papermaking fabrics (forming fabrics, etc.) will be less prone to damage, prolonging their lifespan, hence enabling stable operation of the machine.

In addition, since the size of the filler particle is made larger with the coating, the filler is better retained in the paper, hence the amount of the yield enhancer (agent) added is greatly reduced, leading to resource conservation.

Deinking cake Dehydrating Paper sludge Firing and finishing High-grade reclaimed filler Dehydrator Kiln High-quality reclaimed filler manufacturing facility

Supporting Environmental Recycling by Converting Industrial Waste into Recovered Fuel

Waste plastics, waste home appliances, and discarded automobiles has been disposed of as industrial waste. However, the Daio Paper Group is promoting the recycling of these materials through the following measures (carried out by Daio Engineering).

1) Propose plant-improvement plans to recycling businesses
2) Design and construct facilities to reduce the volume of waste and convert waste into recovered resources and fuels
3) Improve the recycling rate and reduce the final disposal cost of recycling companies
4) Accept the recovered fuels, such as refuse plastic fuels and heat-insulating materials (polyurethane) of refrigerators, for use at the biomass boilers of the six production bases of the Daio Paper Group

Through the effective utilization of wastes across the group, the Daio Paper Group strives to achieve a sustainable society.

Environment Recycling Business Supported by Daio Engineering Co., Ltd.

Support 1 Recovered materials/Raw materials for fuels. Support 2 Recovery of various resources at recycling plant. Support 3 Recycled fuels

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Initiatives to Reduce Final Disposal Amount of Industrial Waste

The Daio Paper Group is promoting the reduction of final disposal amount of solid waste, by switching to intermediate waste treatment companies that recycle waste for the disposal of industrial waste produced in the Group. The total final disposal amount of industrial waste produced by the Group amounted to 4,000 t (1.2% of its total industrial waste) in FY2017.

The amount of industrial waste produced by the Mishima Mill accounted for 75% (261,000 t) of the total of that produced by the Group, but through the promotion of recycling waste into recycled crushed stone and cement raw materials, we achieved a recycling rate of 99.9% at Mishima mill.

Amount of Industrial Waste Produced (Daio Paper Group) Final Disposal Amount of Industrial Waste (Daio Paper Group) Breakdown of Recycled Waste (Mishima Mill)

Initiatives for Recycling Waste Materials

Industrial waste such as ash generated from incinerating sludge from effluent treatment, ash generated by biomass boilers, and sludge generated in the chemical manufacturing process have been recycled mainly into cement raw materials and road bed materials. In addition, we have started to recycle industrial waste into concrete blocks, recycled soil, and sub-materials for steelmaking. As a result, excluding the final disposal (landfill disposal) amount of solid waste, we achieved an industrial waste recycling rate of 98.7%.

Concrete blocks, which are formed by mixing incineration ash and cement and then shaped into cubes, are used as soil retainer blocks to prevent landslides and other disasters. Recycled soil is a certified recycled product, and is made by mixing quicklime and a fixation agent. It is used as an embankment material such as to raise the ground level of low-lying land or the surrounding ground level when constructing roads.

Recycling rate of industrial waste: 98.7% (group-wide)

Supply Chain Management/ Calculation of Scope 1, 2, and 3

The Daio Paper Group believes that by determining and managing its greenhouse gas emissions at every stage of the entire lifecycle, from procurement of raw materials to the use and disposal of products, and thus expanding its scope of reductions in greenhouse gas emissions to include its supply chain, it will lead to increased opportunities for reducing greenhouse gas emissions, and also greater potential for companies to identify cost reduction opportunities.

Through our products and services, we hope to contribute to the reduction of greenhouse gas emissions of other companies, and by declaring the amount of emissions we wish to reduce and work together with our stakeholders to achieve it, contribute to the realization of a sustainable society.

Greenhouse Gas Emissions in the Supply Chain

The Daio Paper Group (FY2016 Results)

Initiatives for Reducing the Amount of PRTR Substances

The Daio Paper Group gives maximum consideration to product safety by appropriately managing the use of chemicals.
We adopt new paper chemicals not just based on their effect on product quality, but also perform in-house evaluations to measure their possible impacts on people and the environment. We also check the safety of chemicals already adopted by requiring the submission of chemical content certificates every year.

Emission Volume of PRTR-listed Chemical Substances

Emission Volume of PRTR-listed Chemical Substances

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Substance
No.
Name of Chemical Substance Unit Volume
Handled
Emission
Volume
Volume
Transferred
1 Water-soluble zinc compounds t 0.6
2 Acrylamide t
20 2-aminoethanol t 0 1.1
48 EPN t 0.6
80 Xylene t 3.2 0.0 0.0
127 Chloroform t 2.5 2.4
134 Vinyl acetate t 0.8 0.2
243 Dioxins mg-TEQ 7.1 2.1
279 1,1,1-trichloroethane t 1.7
296 1,2,4-trimethylbenzen t 3.6
300 Toluene t 737.6 31.1 16.9
333 Hydrazine t
374 Hydrogen fluoride and its water-soluble salt t 2.0 4.3
395 Water-soluble salts of peroxodisulfuric acid t 4.4
405 Boron compounds t 4.5 11.6 0.9
412 Manganese and its compounds t 1.1
438 Methylnaphthalene t 49.8 0.5
total t 808.4 55.2 17.8

Notes:
1. Scope of data collection: Daio Paper Corporation and the production bases of the 15 domestic Group companies
2. Only chemical substances with 1 t or more of volume handled are listed.
3. Dioxins are excluded from output data aggregation due to differences in units of measure used.

Environmental Accounting

  • Scope of calculations: In addition to the Mishima Mill and the Kani Mill of Daio Paper Corporation, and Iwaki Daio Paper Corporation, forestry-related operations of Forestal Anchile Ltda., our Group company in Chile, were included within the scope of calculations for Environmental Conservation Costs and Benefits.
  • Target period: FY2017 (from April 1, 2017 to March 31, 2018)
  • Calculations were performed using “Environmental Accounting Guidelines 2005” released by the Ministry of the Environment.

Environmental Conservation Cost

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(Millions of Yen)

Category Details of major activities Investment Cost
(1) Business area cost 2,830 30,600
①Pollution prevention cost Effluent treatment facilities, deodorizing/exhaust gas desulfurization facilities, ECF, etc. 1,175 5,240
②Global environmental conservation cost Overseas forestation, maintenance and management of company-owned forests, energy-saving 612 1,289
③Resource circulation cost Waste disposal/recycling waste as materials, effective use of recovered paper and other resources 1,043 24,071
(2)Upstream / downstream cost Recycling cost, low-sulfur fuel purchase cost (difference), etc. 999
(3)Administration cost Management cost of ISO14001, cost of employee education, environmental impact measurement, etc. 112
(4)R&D cost Development of products, such as environmentally friendly brands, for environmental conservation, etc. 35
(5)Social activity cost Various volunteer activities, organization support, environmental report, etc. 78
(6)Environmental remediation cost Pollution load charges (SOx) 126
Total 2,777 31,950

Environmental Conservation Benefit

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Categories of environmental
conservation benefit
Environmental load items Unit FY2016 FY2017 Change from the
previous year
(1)Benefit corresponding to
business area cost
①Reduction of greenhouse gas (CO2) CO2 emission volume 1000 t 4,075 3,848 Decreased by
227,000 t
②Reduction of air-pollution substances Sulfur oxide emission volume t 1,109 1,372 Increased by 263 t
Nitrogen oxide emission volume t 6,161 6,209 Increased by 48 t
Dust emission volume t 264 320 Increased by 56 t
③Reduction of water-pollution substances Volume of waste water 1000 m3 126,945 119,365 Increased by 7,580,000 m3
COD emission volume t 7,217 6,978 Decreased by 239 t
SS emission volume t 1,997 1,371 Decreased by 626 t
Nitrogen emission volume t 410 414 Increased by 4 t
Phosphorus emission volume t 48 51 Increased by 3 t
④Promotion of overseas forestation Overseas forested area ha 28,700 28,700
⑤Reduction of industrial waste Volume of industrial waste generation 1000 t 322 322
(2) Benefit corresponding to
upstream / downstream cost
①Promotion of recovered paper usage Volume of recovered paper usage 1000 t 1,784 1,749 Decreased by 35,000 t

Economic Benefits of Environmental Conservation Measures

(Millions of Yen)

Details of benefits Amount
Cost reduction from energy saving 10
Cost reduction from decrease in fossil fuel usage
Reduction of disposal cost due to effective use of waste 48
Cost reduction through the effective use of hard-to-recycle recovered paper 15
Total 73
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