Chemical Substance Management
Basic Concept
The Nisshinbo Group's Business Conduct Guidelines include Awareness and Concern towards its environmental impact. The Group properly manages hazardous substances, implements measures to prevent leakage in accordance with the laws and regulations of each country, strives to properly manage substances contained in its products, and faithfully realizes a safe and secure society for all people. The Group manages key performance indicators (KPIs) as part of systematic measures to reduce the emissions of PRTR* substances per sales, to achieve its environmental target.
【Main measures】
- ①Conducting appropriate control and anti-leakage measures for hazardous materials through ISO 14001 activities in accordance with the laws and regulations of each country
- ②Reducing the use of substances subject to PRTR and reducing the release and transfer of substances subject to PRTR at manufacturing sites
- ③In the Precision Instruments business, switching of cleaning agents used in cleaning processes to products not covered by PRTR
- ④Provide emergency response training for chemical substance leaks
* PRTR substances: Substances subject to the Pollutant Release and Transfer Register (PRTR) system pursuant to the “Act on the Confirmation, etc. of Release Amounts of Specific Chemical Substances in the Environment and Promotion of Improvements to the Management Thereof” and reports of their amounts of release and transfer must be filed.
Please refer to "Promotion System" in "Environmental Activities" for the promotion system.
Specific Initiatives of The Nisshinbo Group
Volume of Chemical Substances Handled
The volume of substances subject to PRTR handled by the Nisshinbo Group was 2,625 t, down 6% year-on-year (YoY). At Nagano Japan Radio Manufacturing Co., Ltd., there was a decrease due to progress in replacing toluene, xylene, and ethylbenzene with substances not subject to the PRTR.
Major items making up the Nisshinbo Group’s volume of PRTR substances handled were antimony (639 t) and chromium (330 t) for brake materials, as well as methylenebis (4,1-phenylene) diisocyanate (688 t) and methylenebis (4,1-cyclohexylene) diisocyanate (387 t) for urethane materials.
The Automobile Brakes business accounted for 47% of the overall volume of chemical substances handled by the Group.
Trends in the Volume of PRTR Substances Handled
* In 2018, we changed our fiscal year-end from March 31 to December 31. As a result, the consolidated fiscal year, which is a transitional period, is an irregular accounting period. For this reason, the period used for reference to FY2018 is adjusted to the period from April 1, 2018 to March 31, 2019, to match the period of other consolidated fiscal years.
Volume of PRTR Substances Handled by Business
Volume of Chemical Substance Emissions
The Nisshinbo Group's volume of PRTR substance emissions totaled 21.2 t, up 20% year on year. Volume of PRTR substance emissions per unit of sales was 0.041 kg per million yen, up 20% year on year. At Toms Manufacturing Corporation in the Precision Instruments business, emissions of PRTR substances into the environment increased because of the newly started use of a cleaning agent.
Trends in Volume of PRTR Substance Emissions and Volume of PRTR Substance Emissions per Sales
* In 2018, we changed our fiscal year-end from March 31 to December 31. As a result, the consolidated fiscal year, which is a transitional period, is an irregular accounting period. For this reason, the period used for reference to FY2018 is adjusted to the period from April 1, 2018 to March 31, 2019, to match the period of other consolidated fiscal years.
Emission Breakdown by Chemical Substance
| Chemical Substance | Discharge Amount(t) | Ratio |
|---|---|---|
| Toluene | 7.9 | 37.3% |
| Xylene | 3.9 | 18.1% |
| Ethylbenzene | 2.3 | 11.0% |
| 1-Bromopropane | 1.7 | 7.9% |
| Hexamethylenetetramine | 1.3 | 6.2% |
| Phenol | 1.3 | 6.1% |
| Others | 2.8 | 13.4% |
Toluene accounted for the highest proportion of emitted chemical substances, at 37% of the total.
By business, the proportion of the Precision Instruments business releasing xylene and 1-bromopropane was 48% of the total.
Volume of PRTR Substances Emitted by Business
*1 In 2018, we changed our fiscal year-end from March 31 to December 31. As a result, the consolidated fiscal year, which is a transitional period, is an irregular accounting period. For this reason, the period used for reference to FY2018 is adjusted to the period from April 1, 2018 to March 31, 2019, to match the period of other consolidated fiscal years.
*2 In FY2019, the Electronics business was separated into the Wireless and Communications business and the Micro Devices business.
Purification of Wastewater
The Nisshinbo Group's volume of suspended substances (SSs) emissions per unit of sales totaled 0.18 kg per million yen, up 1% year on year. The volume of CODs* emissions per unit of sales was 0.26 kg per million yen, up 14 % year on year. This was due to a recovery in production in the Textiles business and an increase in wastewater discharges.
* Chemical Oxygen Demand (COD): An index of water contamination expressed as the volume of oxygen chemically required or chemically consumed
Trends in Amount of SSs Emissions per Unit of Sales and Amount of CODs Emissions per Unit of Sales
* In 2018, we changed our fiscal year-end from March 31 to December 31. As a result, the consolidated fiscal year, which is a transitional period, is an irregular accounting period. For this reason, the period used for reference to FY2018 is adjusted to the period from April 1, 2018 to March 31, 2019, to match the period of other consolidated fiscal years.
Atmospheric Releases
The Nisshinbo Group's sulfuric oxides (SOx) emissions per unit of sales was 0.07 kg per million yen, down 86% YoY. Nitrogen oxides (NOx) emissions per unit of sales was 0.09 kg per million yen, down 83% YoY. Volatile organic compounds (VOCs*) emissions per unit of sales was 0.13 kg per million yen, down 52% YoY. Soot and dust emissions per unit of sales was 0.02 kg per million yen, unchanged down 78% YoY. This was due to the fact that PT. Nikawa Textile Industry in the Textiles business stopped using coal boilers to generate electricity from November 2021, resulting in a significant reduction in the amount of coal used.
* Volatile Organic Compounds (VOCs): Volatile organic compounds such as toluene
Trends in Amount of SOx Emissions per Unit of Sales, Amount of NOx Emissions per Unit of Sales, Amount of VOCs Emissions per Unit of Sales and , Amount of soot and dust Emissions per Unit of Sales
* In 2018, we changed our fiscal year-end from March 31 to December 31. As a result, the consolidated fiscal year, which is a transitional period, is an irregular accounting period. For this reason, the period used for reference to FY2018 is adjusted to the period from April 1, 2018 to March 31, 2019, to match the period of other consolidated fiscal years.
Specific Activities of the Group Companies
Efforts to Prevent Leakage of Environmentally Hazardous Substances
Nagano Japan Radio Co., Ltd., Head Office Factory, conduct emergency response training once a year to prevent leakage of environmentally hazardous substances outside the premises in case of leakage into soil or waterways due to overturned or broken containers, since the drainage canal on the premises is connected to an adjacent agricultural waterway.
In FY2022, 13 representatives from departments managing hazardous material storage facilities participated in the training on October 19. The training included the following: ①confirmation of basic storage containers and handling procedures, ②confirmation of the emergency contact system in the event of a leak, ③confirmation of response procedures and hands-on training (e.g., checking and damming drainage canal weirs, installing oil fences in onsite drainage canals, pumping out hazardous substances using adsorbent sheets and ladles), and ④confirmation of emergency response storage equipment and storage locations. The participants are required to disseminate the information from the training to all employees in their own divisions to raise their awareness of environmental conservation.
Reducing the Risk of Chemical Contamination by Conducting Emergency Training on Wastewater Treatment
NJ Components Co., Ltd., Sanyo Office, uses caustic soda (alkali) and sulfate bands (acid) as neutralizing agents at its wastewater treatment facility. Since the treatment facility is located close to residences, there is a risk of damage to nearby residents due to soil contamination in the event of a leakage accident. Leakage due to problems at the wastewater treatment facility does not always occur during weekdays when management is present.
Currently, inspections are conducted on holidays and at night by workers who are knowledgeable about the facility and how to deal with problems. However, problems can occur at any time. Therefore, the company provides the following training for the two workers who conduct inspections on holidays and at night when the manager is not available, in order to prevent soil contamination and to avoid causing damage to nearby residents.
- ①Confirmation of the number of sandbags stored, their deteriorated condition, and location
- ②Checking the operation of drainage pumps
- ③Training on how to respond to a hypothetical leak
Checking the hazards of chemicals using SDS and first aid methods, and safety training was also provided.
Hazardous Waste and Hazardous Chemicals Leak Response Training
In April 2022, Nisshinbo Saeron Automotive (Changshu) Co., Ltd., in China conducted a hazardous waste and hazardous chemical leakage training. Twenty-five employees from the departments that handle hazardous waste and hazardous chemicals departments and the emergency rescue teams participated in the training.
The trainig was based on the premise of a worker transporting a hazardous waste chemical with a forklift damaged a valve on a container tank by mishandling on-vehicle operations and causing a leak.
As soon as the leak was confirmed, emergency supplies were used in the warehouse to prevent leakage of the hazardous waste, and the situation was reported to the General Affairs Section, which requested assistance. The General Affairs Section notified the emergency rescue team via an in-house broadcast system, and the emergency rescue team (emergency support team, evacuation team, and accident investigation team) was on site to handle the leak (e.g., replace containers, organize leaked materials on the ground, and close rainwater valves), and after the initial emergency treatment, washed the hazardous waste remaining on the ground with tap water and collected the cleaning water for treatment at the sewage treatment facility. Finally, samples of rainwater were taken, and the results of the tests performed by an outside party passed the tests, and the alarm was lifted.
Simulation Training for Hazardous Waste Leakage
PT. Standard Indonesia Industry in Indonesia provides training with the goal of ensuring that line process leaders can respond quickly in the event of a hazardous material leakage incident at the site.
B3 is an acronym for Bahan (substance), Berbahaya (hazardous), dan Beracun (toxic), which is the Indonesian industry standard. B3 is a substance or physicochemical hazardous substance that may endanger human health or environmental sustainability. B3 is required by law to be used and controlled with care.
In July 2022, 10 people from each department participated in a simulation training session to simulate a leak of B3 hazardous substances.
Oil Leak Emergency Response Training
At Excel Tokai Co., Ltd., emergency response training is provided once a year for new employees on the assumption of oil leakage accidents during oil changes for machinery and equipment and during waste oil disposal.
In FY2022, oil spill prevention training was provided for five new employees on August 8, assuming that an oil drum had fallen over. Based on the Oil Leakage Incident Response Procedures, the training was provided so that employees can learn the procedures for the following two situations.
- ①Oil leaks on the floor should be prevented by using adsorption socks and mats to prevent damage from the source of the leak.
- ②Assuming the oil leaks into the drainage pit, procedures are initiated for dealing with the area around the water tank drain to prevent oil from leaking out of the plant.
Reduction of PRTR Substance Consumption by Introduction of Equipment
Nisshinbo Chemical Inc., Tokushima Plant, manufactures carbodiimide. Carbodiimide is produced by polymerizing isocyanate to a polymer through a polymerization reaction, and the progress of this polymerization reaction is monitored by monitoring the isocyanate concentration (NCO% value).
In June 2022, FT-NIR equipment (near-infrared spectrometer) was installed in three reaction vessels, and the method of calculating NCO percentage values using the reagents of toluene and xylene, which had been done manually by workers, was changed to a method where the reaction state can be monitored by NCO percentage values measured in real time by the FT-NIR equipment.
As a result, the work time was reduced by one to two hours, which then allowed the operator to proceed with the production process of other reaction vessels. Furthermore, the number of reagents used for analysis that fall under PRTR substances has been reduced by 24% compared to FY2021.
Strengthening Fire and Leakage Response Capabilities in the Event of an Earthquake
Nisshinbo Chemical Inc., Tokushima Plant, uses a variety of chemicals and conducts production activities around the clock. To ensure that each employee is able to respond appropriately to fires and chemical leak emergencies triggered by earthquakes, workplace trainings are conducted every year under a variety of different scenarios with day and shift workers taking the lead.
Each representative issues instructions to personnel, communicates with external parties like the fire department, and explains the situation. To ensure that information is provided without omission, a simplified safety data sheet (SDS) list of chemical substances used in production and a backpack containing a map of the business site are carried during the evacuation. In the FY2022 workplace drill, the company conducted a scenario of a chemical leakage and fire event caused by an earthquake, and company personnel were able to smoothly respond to everything from equipment shutdown operations after the earthquake to personnel roll calls, the sharing of damaged equipment, and instructions on appropriate measures based on the properties of the leaked chemicals.
OEKO-TEX® STeP Certification
PT. Nisshinbo Indonesia in Indonesia has acquired OEKO-TEX® STeP certification.
OEKO-TEX® is an international certification system for evaluating the quality and safety of textile products, and STeP is a certification that proves how sustainable the system is for factories and companies producing textile products. Specifically, the following criteria are established:
- ①Employee safety and health management
- ②Chemical substance management
- ③Quality control
- ④Social responsibility
- ⑤Impact on the global environment
The company believes that OEKO-TEX® STeP certification will provide higher quality and more sustainable products to customers and realize the environmental and social considerations.
Liquid Ammonia Processing Facility and Emergency Trainings
Nisshinbo Textile Inc., Yoshinogawa Plant, uses several chemicals in the processing of woven and knitted fabrics. Because some processes use liquid ammonia, the plant has equipment for collecting, storing, and reusing the ammonia gas generated during processing.
Since this equipment is subject to the High-Pressure Gas Safety Act, the plant is equipped with water sprinkler systems for emergencies, emergency generators, air respirators, and multiple gas detectors, and safety inspections are conducted annually by a designated agency.
In addition, emergency test trainings are conducted for workers to prepare them to respond to unforeseen situations, such as water sprinkler trainings for ammonia leakage and trainings for wearing air respirators. (Conducted in FY2022 with seven participants) The participants were trained in the ①inspection of equipment necessary for an emergency response, ②water sprinkling procedures in case of ammonia gas leakage, and ③the procedures in the case of abnormal PH values in the cooling water pit with explanations from security staff.
