Report on - Siegfried

Overview 2003 – 2007 1Key corporate figuresResourcesNumber of employees12001000800600400200Total energy consumption (1,000 giga joules)400300200100020072006200520042003020072006200520042003Number of SHE audits Zofingen (ZO) and Pennsville (PV) facilities250200150100500200720062005200420031If not specified, data valid for all of Siegfried54 <strong>Report</strong> on “Safety – Health – Environment”

Emissions 1Industrial effluent / Zofingen & Pennsville (1,000 m 3 )800Chemical wastes w/o effluent sludge (1,000 tons)256004002002015105020072006200520042003020072006200520042003CO2 emissions (1,000 m 3 )2015105VOC emissions (tons)120100806040200200720062005200420030200720062005200420031If not specified, data valid for all of Siegfried<strong>Report</strong> on “Safety – Health – Environment”55

Resource consumption2003 – 2007 overviewUnit 2007 2006 2005 2004 2003Total energy GJ 376 000 373 000 379 000 344 000 360 000Natural gas GJ 192 000 202 700 186 500 191 000 198 000Heating oil GJ 22 500 21 200 13 000 11 000 18 000Alternate fuels (solvents) TAR GJ 29 000 14 000 57 000 27 000 22 000Electricity GJ 126 000 129 000 119 000 110 000 117 000Water m 3 1 600 000 1 940 000 1 761 000 1,437 100 1 887 100CommentsInvestments in new energy systems and modern productionsystems and control systems stabilize energy consumption.For the first time, a full 12 months of activity for the newpharmaceutical facility in Malta was added to our resourcebalance sheet, with a proportional increase in energy consumption.Fortunately, the growth trend in electric powerconsumption was stabilized – despite increased use of airconditioning. Electric power consumption in Pennsvilledripped by 5% thanks to lower utilization levels.Fossil fuels saw a shift from natural gas to alternativefuels (solvent-based). The increased use of such alternativefuels to power the thermal emission control (TAR) systemsand to provide steam for production processes enabled afurther reduction in the external disposal of waste solvents.The increase in the use of heating oil is the result of runningenergy intensive processes (such as high temperature reactions)in production.Zofingen, today already over 50% of the wastewater canbe released into the environment as clean cooling water. The“water savings” goal for Zofingen was met.Goals 2008Zofingen and Pennsville– Updating the heating/cooling system– Stabilize energy use (cooling, air-conditioning)– Optimize savings potential of:– Installing energy-saving bulbs and motion detectors– Saving water in Zofingen– Saving nitrogen in PennsvilleThanks to updated heating / cooling systems and optimizedcooling water circulation loops, overall water consumptionwas reduced across the company by just 18%. The systematicseparation of sewage and cooling water led to a clearreduction in the amounts of wastewater to be treated. In56 <strong>Report</strong> on “Safety – Health – Environment”

Emissions2003 – 2007 overviewUnit 2007 2006 2005 2004 2003Chemical wastes w/o effluent sludge Tons 11 700 16 800 13 500 10 900 13 400Industrial effluent / Zofingen m 3 292 000 349 000 412 400 330 000 504 000Pennsville m 3 56 400 62 200 53 500 59 100 62 800CO2 emissions Tons 15 600 14 780 17 011 14 453 15 300VOC emissions Tons 48 62 57 51 104CommentsLarge amounts of contaminated solvents result from theproduction of pharmaceutical ingredients (due to productionprocesses and regulatory guidelines). Recycling efforts are limitedby cGMP regulations, avoidance of cross contamination,or product safety.Thanks to an “in-process recycling” method, over 2,000 tonsof solvents were recycled for use in the production process,eliminating the need to incinerate the solvents – and addinganother 6,000 tons of CO2 to the environment. The amount ofwaste solvents in both the Zofingen and Pennsville facilitieswas reduced by around 30%, due to lower utilization levelsand shifts in the product mix. Zofingen increasingly producedsmall batch products.Industrial effluent: the long-term goal to “save water”has also resulted in a decrease in the production of effluent, asthe amount of highly contaminated industrial effluent wasclearly reduced. The multi-year program to reduce refractoryeffluent substances was rigorously maintained. The amount oforganic effluents in Zofingen was reduced from over 500 tonsto less than 430 tons by implementing technical process measuresand targeted processing of critical effluent streams.VOC: Zofingen managed to maintain a low level of VOC emissionswith the use of a thermal emission control system (TAR)and a (low emission) solvent exchange. Pennsville is the sourceof 2/3 of the VOC emissions. Due to technical reasons, availabilityof the exhaust air filtering system was limited. Fortunately,overall VOC emissions were reduced and our goal wasmet.Goals 2008Zofingen and Pennsville– Reduction of persistent compounds in the effluent– Further optimization of recycling processes (solvents)– Reduction of VOC emissions due to high availability ofthermal air cleaning system– Optimization of the waste water treatment in Pennsville(reduction of amount of virgin acid) and suspendedparticlesThe effluent monitoring program, “Single Material Analytics”was successfully continued and now encompasses a library ofmany dozen intermediate and end products. These materialscan be analyzed in the effluent with modern analytic measures.This program helps Siegfried reduce pollution by minimizingthe amount of undesirable pharmaceutical ingredientsin the water. The implementation of this program – a keytask/goal – will be continued.Carbon dioxide: Numerous factors led to an increase in CO2emissions. Zofingen burned more heating oil and solvents;which have a higher carbon content than natural gas and producemore CO2 during incineration. The new facility in Maltawas operational for a full year for the first time.<strong>Report</strong> on “Safety – Health – Environment”57

Goals 2008Zofingen and Pennsville– Less than 10 accidents with lost workdays per 1,000employees and less than 140 lost days due to accidentsper 1,000 employees.– Less than 35 accidents in total per 1,000 employees.– Quicker return to work through availability of lightduty jobs.– Implementation of health awareness campaigns<strong>Report</strong> on “Safety – Health – Environment” 59