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.
※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).
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.
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.
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.
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.
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.
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.
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.
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
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|Name of Chemical Substance||Unit||Volume
|1||Water-soluble zinc compounds||t||0.6|
|374||Hydrogen fluoride and its water-soluble salt||t||2.0||4.3|
|395||Water-soluble salts of peroxodisulfuric acid||t||4.4|
|412||Manganese and its compounds||t||1.1|
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.
- ①Scope 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.
- ②Target period: FY2017 (from April 1, 2017 to March 31, 2018)
- ③Calculations 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|
Environmental Conservation Benefit
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|Categories of environmental
|Environmental load items||Unit||FY2016||FY2017||Change from the
|（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|