Strong Strides Toward Sustainability in the Abrasives Industry
Sustainability has become a critical area of focus for many global companies in the manufacturing sector as more government agencies and industry organisations set goals and standards that prioritise sustainability.
For companies based in or operating in the European Union (EU), implementing sustainability plans is partly driven by the EU Corporate Sustainability Reporting Directive (CSRD). This policy requires large companies and public-interest entities operating in the EU to publish regular reports on the social and environmental risks they face and on how their activities impact people and the environment by 2025. The EU has committed to ambitious, long-term environmental and climate goals, also aiming to be climate-neutral by 2050 — an economy with net-zero greenhouse gas emissions.
These types of initiatives and many other factors are spurring companies, including Weiler Abrasives, to action regarding sustainability and the environmental impact of manufacturing and production.
A priority across the operation
At Weiler Abrasives, which has a manufacturing operation based in Slovenia, there is a holistic and strategic approach to corporate sustainability. The aim is to include it as a priority and consideration in every aspect of the operation — from product development and procurement to waste disposal and facility improvements.
Weiler Abrasives is developing its own list of sustainability priorities that will include a strategy and timeline for future efforts. The company understands that sustainability efforts require continuous processes with constant improvement and evolution; it is not just a single project that can be completed with a checkmark. Sustainability is also a key driver of product innovation, embedded in company strategy and day-to-day thinking.
Weiler Abrasives has a holistic and strategic approach to corporate sustainability.
As a founding member of SEAM (Sustainable European Abrasives Manufacturers), Weiler Abrasives is aligned with peers in achieving common sustainability goals specific to the abrasives industry. SEAM is dedicated to helping the European abrasives industry embrace environmental, social, and economic sustainability to maintain its global leadership position and move the industry forward. The organisation has pillars focused on managing emissions, waste, and energy use, among other priorities. Members must also meet a sustainable production process certified by the EU.
In addition, Weiler Abrasives’ operations are monitored and comply with the ISO 14001 environmental standard, which helps organisations improve their environmental performance through more efficient use of resources and waste reduction, gaining a competitive advantage and the trust of stakeholders.
Key initiatives underway at Weiler Abrasives
Although formalized sustainability objectives are pending, the company is proactively implementing a range of measures aimed at enhancing sustainability efforts. From reducing waste to decreasing the carbon footprint, here is a look at some key initiatives that are underway:
- Scrap recycling: The Weiler Abrasives facilities in Slovenia have their own recycling plant, making it possible to recycle the scrap produced in the abrasive manufacturing process. A substantial portion of the recycled material is then reused in other products. The company has been able to improve its yields of waste recycling by 128 tons of incrementally reused materials in the last year.
- Innovative product development: Another key focus is improving existing products and developing new products that play a role in environmental sustainability. One way to do that is to reduce or eliminate certain chemicals used when manufacturing abrasives and replace them with non-toxic options, reducing air and groundwater pollution. In addition, developing longer-lasting products provides sustainability benefits for customers by extending product life and reducing their abrasive waste.
- Commitment to renewable energy: The addition of two photovoltaic systems at the Maribor and Zreče manufacturing facilities represent a significant commitment to harnessing clean, renewable solar energy. The installation is designed to contribute up to one-fifth of Weiler Abrasives’ electricity requirements in its Slovenian facilities and, as a result, decrease nearly 900 tons of CO2 emissions annually through climate-friendly solar energy. The systems deliver a combined output of 1,839 kWp, generating electricity that is equivalent to the demand of about 1,000 households and decreasing CO2 emissions by the equivalent of 500 medium-sized cars.
- Responsible supplier selection: In the abrasives industry, more than 50% of the carbon footprint during the manufacturing process lies upstream in the supply chain in raw material manufacturing. This makes it critical to choose suppliers who share your sustainability values and make it a priority. Manufacturers like Weiler Abrasives must work closely with suppliers first and foremost to find sustainable solutions and work with suppliers to reduce the downstream effects. If a company has multiple vendor options, choosing one that is aligned with your environmental, social, and governance (ESG) policies is important. For example, carbon neutrality may be a key decision factor for many companies in choosing a vendor.
- Measuring CO2 impact: Keeping track of emissions in all aspects of the operation — upstream, during manufacturing and downstream — helps provide a clear view for a company to set goals and make improvements. Weiler Abrasives intends to join the EU industry initiative to be carbon neutral by 2050.
- Facility improvements: The company is committed to constantly increasing the share of renewable energy sources used in the operation. The first step is producing 20% of the company’s electricity with solar resources. In addition, a new heating, ventilation, and air conditioning (HVAC) system installed in the manufacturing facility is expected to decrease energy consumption fivefold in selected plant areas.
Helping customers improve their operations
Beyond the sustainability steps taken within their own operations, Weiler Abrasives also works to educate customers and help them improve sustainability in numerous ways. In some applications, up to one quarter of emissions related to the company’s operation occur downstream once customers use the abrasive products. Due to this, Weiler Abrasives has made it a priority to reduce emissions at this stage of the process as well.
One way to help reach that goal is by developing products that promote sustainability and have a reduced environmental impact. New Metalynx 2.0 cutting, grinding and combo wheels last up to 40% longer to increase efficiency in cutting and grinding applications.
The grinding wheels feature anti-chipping technology, an advanced bond formulation that eliminates uneven edge wear and chipping to extend wheel life. They also use an award-winning blotter design with an industry-first, patent-pending Optimum Use Line. The line is a visual indicator that helps the user utilise the wheel to its full life. This innovation reduces changeovers and reduces waste. In some cases, users experience three times more efficiency than with their previous abrasives.
The Optimum Use Line reduces changeovers and waste.
Another way the company assists customers with sustainability is through the Weiler Consumable Productivity (WCP) program, which helps end users better manage their abrasives costs and increase productivity. The WCP program tests and evaluates abrasives to compare product life, reduce cycle times, and increase efficiencies. Because it can pinpoint whether customers are scrapping products too soon or using techniques that prematurely shorten product life, for example, it can help users eliminate those practices and reduce product waste.
An ongoing commitment
While many of the company’s sustainability efforts are in ramp-up stages, Weiler Abrasives has made this commitment a priority. Sustainability is critical for large corporations and manufacturers that want to compete globally in the years ahead. It is important for abrasive manufacturers to analyse their own internal efforts to make production more sustainable while also working with suppliers and customers to make improvements upstream and downstream for an even greater impact.
Rok Mezgec,
Director – Supply Chain and R&D,
Weiler Abrasives
The Weiler consumable productivity program (WCP):
The Weiler Consumable Productivity (WCP) program specializes in enhancing cutting operations in fabrication facilities, particularly where there's a lack of resources or methods to measure outcomes. WCP stands as a tested approach, focusing on efficiency, and providing real-world data to pinpoint opportunities for cost and time reductions.