Environmental Report - Volkswagen Autoeuropa

Autoeuropa 

Environmental 

Report 

2007



Report 

2007 

© Volkswagen Autoeuropa

Contents 

P 04 

1. 

ENVIRONMENTAL STRATEGY 

Management commitment 

Environmental Policy 

P 10 

2. 

WHAT IS VOLKSWAGEN AUTOEUROPA 

Plant 

Products 

Process 

P 16 

3. 

ENVIRONMENTAL CERTIFICATION AND LICENSING 

Evolution of the Environmental Management System 

The Environmental Control and the ISO14001 Team 

Internal audits 

Emergency response 

Environmental training and awareness 

Organization and cleanliness 

2

Environmental Report 2007 

4. 

ENVIRONMENTAL ASPECTS AND THEIR CONTROL 

P 22 

Environmental aspects 

Waste 

Wastewaters 

Atmospheric emissions 

Noise 

Water consumption 

Natural gas consumption 

Energy consumption 

Soil protection 

Materials approval 

Transportation 

Influence over suppliers 

5. 

ENVIRONMENTAL OBJECTIVES AND RESULTS 

P 32 

Objectives and results 2007 

Some examples of implemented programmes 

Objectives for 2008 

6. 

ENVIRONMENTAL INDICATORS 

P 42 

Vehicle production 

Consumption of natural resources and energy 


Waste production 

Wastewaters 

Environmental noise 

7. 

ENVIRONMENTAL COSTS AND INVESTMENTS 

Running costs 

Investments 

P 52 

3

766,03 

0,72 

342

222,4 

(Kg/h) 

42,306 

1. 


strategy

Management 

commitment 

Nowadays, the environment and the efficient management of 

the natural resources and energy, along with the economical and 

social factors are the base pillars of the modern and developed 

countries, as well as the guidelines of the solid companies. 

In order to achieve a sustained growth, Volkswagen Autoeuropa 

promotes these fundamental variables and reaffirms its 

commitment to the fulfilment of the objectives of environmental 

responsibility. 

We design processes aiming for the efficient use of resources, 

minimizing the energy consumption, the production of 

emissions and waste, seeking for a low environmental impact. 

Moreover, we advise and influence our suppliers to act in line 

with our Environmental Policy. 

In the daily work we reinforce continuously our efforts in the 

accomplishment of the Environmental Policy, by promoting 

the necessary training and education to our collaborators, by 

attributing them a clear responsibility and mission in this scope 

and by creating an environmental awareness. 

We will support changes in processes and the use of 

alternative energies and we bear in mind that the existing 

natural resources are not unlimited, and that there is the 

urgent need to encourage their rational use and exploitation. 

Therefore, we will reinvent new methods and strive for the 

preservation of our common heritage and its transmission to 

the coming generations. 

The objective of the present Report is the publication of the 

results of our environmental performance in 2007. 

Andreas Hinrichs 

Executive Director of 

Volkswagen Autoeuropa 

6


Environmental strategy 

In 2007, we renewed our environmental certification 

for the third time. 

As the management representative for the 

environmental issues, this fact is a motive of great 

satisfaction for my team and me. 

In current times, it’s no longer possible for a big 

company like Volkswagen Autoeuropa, to do 

business with a long-term view not addressing the 

environmental matters as part of its strategy. Adopting 

sustainability as a way of doing things ensures not 

only the reduction of the environmental impacts of 

our activity, but also the baseline for our economic 

growth and the social recognition of the work we’ve 

been developing. 

By involving our main suppliers in this process, we 

share with them the environmental challenge that we 

assumed ourselves, and create synergies that lead to 

much better global results than the ones we would 

achieve on our own. 

Year after year is harder and harder to define new 

objectives and improvement opportunities, as well 

as to positively respond to an increasing pressure 

of the legislative evolution. Yet I’m confident that 

Volkswagen Autoeuropa will continue to do its best 

on this field, and will continue to be recognised as 

leader in protecting the environment. 

Within the frame of the current climate changes 

and the urgent need to rationally use natural and 

energetic resources, industry has an increasing 

responsibility towards the adoption of a responsible 

and sustainable attitude. Ecoefficiency provides 

the only way for industry to grow economically 

yet maintaining its commitment to preserve the 

environment for the future generations. 

It is important that we’re daily aware of the impact 

of our gestures and all that lies in our hands to 

do: saving water and energy, adequately segregate 

waste to enable its recovery whenever possible, 

efficiently control of activities and equipment. But 

being aware is not enough, we must act. We must 

be the driving force for changes, either internally 

or in partnership with our suppliers. I believe this a 

vision worth fighting for. 

To give our best for a good harmony with the 

environment is not an option but a mission… This 

mission is the foundation of the Environmental 

Management System of Autoeuropa that I’m 

proud of as a manager and a citizen. And when I 

receive the very positive comments issued by our 

certification body year over year, I know we’re on 

the right way and get motivated to support new 

and more ambitious environmental objectives. 

Bruno Torres 

Planning, Environment and 

Infrastructures Area Manager 

Pedro Lourenço 

Infrastructures and Environment 

Manager 

7

8


Environmental strategy 

Environmental Policy 

It is the global environmental policy and strategy of Volkswagen Autoeuropa to 

become a recognised leader in protecting the environment. 

This Environmental Policy Statement covers all activities at the Palmela plant, 

whether directly or indirectly involved with the manufacture of our products. 

It is also Volkswagen Autoeuropa policy to seek for continual improvement in 

environmental performance, and where possible to control environmental aspects at 

the source. In particular we aim to: 

• Meet or go beyond 

environmental legal and other 

requirements. 

• Maintain procedures and means 

to deal promptly and effectively 

with environmental emergencies. 

• Establish objectives and 

programmes for the reduction 

of environmental impacts of 

our activities. 

• Ensure that the environmental 

aspects of new manufacturing 

processes, works and related 

service activities are analysed. 

• Promote an increase of valueadding 

destinations for waste. 

• Ensure a clear definition of 

environmental objectives and 

responsibilities. 

• Influence our contractors and 

suppliers in order to meet 

the Volkswagen Autoeuropa 

environmental requirements. 

• Create or maintain green 

areas within or in the 

neighbourhood of Volkswagen 

Autoeuropa. 

9

H 2 

0 

65 

0,33

766,03 

(ml/m 3 ) 

33 

2. 

What is 

Volkswagen 

Autoeuropa

Plant 


is located in the 

Setúbal Peninsula, 

more specifically in the 

Palmela municipality. 

The total plot area of the 

plant is 1 133 339 m 2 

with a covered area of 

245 139 m 2 . 

It was built on a previously unoccupied site, 

north of the Lisbon / Algarve highway, south 

of the Lisbon / Setúbal railway, and next to the 

Penalva railway station. 

The Volkswagen Autoeuropa plant was built 

between 1991 and 1994, having started series 

production in 1995. It has an installed capacity 

for the production of 180 000 vehicles per 

year, if operating in 3 shifts. It is the result of a 

1970 million euros investment and constitutes 

one of the most modern industrial units in 

portuguese territory. 

Since the initial layout, the plant was already 

subjected to a wide set of extensions and 

upgrades, having in view the production of 

new models. However, an effort to optimise 

and reuse the existing buildings was done, in 

order to prevent unnecessary soil occupation. 

A8 

A1 

Tejo Estuary 

Reserve 

Porto 

Alto 

Vasco da 

Gama bridge 

Penalva 

Railway Station 

Cascais 

A5 

25 de Abril 

bridge 

LISBON 

Montijo 

River Tagus 

Moita IC32 

Barreiro 

A12 

A2 

Visitors 

Industrial 

Park 

A2 


Industrial 

Park 

Atlantic 

Ocean 

Arrábida 

Natural Park 

Palmela 

SETÚBAL 

Sado 

Estuary 

Reserve 

Tróia 

Makro 

A2 

Setúbal Peninsula 

Industrial Park of Autoeuropa 

12


What is Volkswagen Autoeuropa 

Products 

The year 2007 was dominated by 

all plant preparations to produce 

the Volkswagen Scirocco, a new 

model inspired by the legendary 

product of the 70’ that will enter 

the market as from the first 

semester of 2008. 

The new Scirocco was presented to the public in 

2006 still as a concept-car and in 2007 was partially 

redesigned to its final shape and approved by the 

Volkswagen Board. 

The main modification to accommodate this new 

model in the plant was the installation of a brand 

new body construction line, where innovative 

technologies were introduced, e.g.: laser brazing 

and indirect spotwelding (used for the first time in 

Volkswagen Group). In the remaining areas of the 

plant there weren’t any changes in equipment or 

technology, given the fact the Scirocco will be built 

in the same line as the current Volkswagen Eos. 

93 609 vehicles were produced during 2007 and the 

Eos represented about 60% of the total. Regarding 

the multipurpose vehicle segment (MPVs), that 

was the reason for Volkswagen Autoeuropa to 

be established, 38 049 units were produced. The 

Volkswagen Sharan and the SEAT Alhambra 

corresponded to 25 and 15%, respectively, of the 

total volume produced in 2007. 

Still in 2007, the Volkswagen Eos enabled the 

Volkswagen brand to be awarded as the first 

worldwide manufacturer to anticipate compliance 

with the recyclability targets for end-of-life 

vehicles. 

13

14


What is Volkswagen Autoeuropa 

Process 

1 

2 

3 

The vehicle manufacturing process at 

Volkswagen Autoeuropa is sequential and 

begins with the cutting of the different 

panels from steel coils in the press-shop. 

A single press-shop produces the panels 

for all models manufactured at Volkswagen 

Autoeuropa although some parts come 

from external suppliers. 

The next step is the body construction, 

where the vehicle structure is built using 

different welding and sealing technologies. 

6 

7 

The assembly process is carried out in 

two independent lines. One of these, 

the older, is solely dedicated to produce 

the MPVs Sharan and Alhambra. In the 

other one, younger and more flexible, 

the Eos is currently produced and in the 

near future the Scirocco as well. 

Common check and test zones await all 

models at the end of the assembly lines, 

and those include a water-test and a 

test-track. The expedition area is also 

common to all models. 

1 

4 

At Volkswagen Autoeuropa, the welding 

lines for the MPV, the Eos and the future 

Scirocco are independent, but they get 

together in a common metal finishing area 

before the vehicles are delivered to the 

paint-shop. 

2 3 

5 

The next step is the painting of the 

finished body, and all models pass through 

the single existing paint-shop. 

4 5 6 7 

15

766,03 

(ml/m 3 ) 

2,02 

332

66,01 

3. 


Certification 

and Licensing

18


Environmental Certification and Licensing 

Evolution of the Environmental 

Management System 

In 1998, Volkswagen Autoeuropa established an Environmental Management 

System (EMS) according to the requirements of the ISO 14001:1996 Standard. 

The system was certified by the VCA (Vehicle 

Certification Agency) in December 1998, and 

this certification has been renewed threefold 

(2001, 2004 and 2007). Every semester, followup 

audits are conducted by VCA, and every three 

years the ISO 14001 certification is renewed. 

During 2005 the successful EMS transition to the 

ISO 14001:2004 Standard was conducted, with 

the attainment of the respective certificate in 

December. 

Volkswagen Autoeuropa is also detainee of the 

Environmental Licence nr. 01/2004 issued by the 

Environment Ministry in February 2004, thus 

anticipating compliance in more than 3 years 

with the dead-line established by the European 

Commission. 

The Environmental Control 

and the ISO14001 Team 

Volkswagen Autoeuropa has a section designated as Environmental 

Control, within the Infrastructures and Environment division. 

The Environmental Control consists of a team 

of two engineers dedicated to the actions of 

environmental control and to the coordination 

and maintenance of the EMS. 

The EMS, in turn, manages and controls all 

environmental aspects of the plant, and also includes 

the programmes necessary to the continuous 

improvement of the environmental performance. It 

also includes the tools to evaluate environmental 

performance evaluation, legal compliance and 

compliance with the ISO 14001:2004 Standard. 

The Environmental Control is supported by a 

group of representatives from each area of the 

plant which, as a group, form the ISO 14001 

Team. This team has meetings every two weeks, 

focussing on, amongst others, the EMS operation 

as well as its improvements. 

Some of the most important functions of the ISO 

14001 Team are to ensure the EMS maintenance in 

each area and to provide all necessary information 

and indicators for the evaluation of the plant’s 

environmental performance. 

Internal audits 

The main tools used for the evaluation of the efficiency of the EMS 

are the internal audits and the management reviews. 

In the annual internal audits programme, about 

20, all areas are contemplated, and have all the 

requirements of the ISO 14001 Standard and the 

legal requirements as their baseline. These audits 

are undertaken by a group of internal auditors. The 

results are weekly reported to the Area Managers. 

The results of the internal audits, of the 

environmental objectives, and of a whole set 

of performance indicators, are analysed by the 

management twice a year. The management 

reviews produce new environmental objectives 

and recommendations for improvement. 

19

20


Environmental Certification and Licensing 

Emergency response 

One of the essential rules of an EMS is to be 

prepared to react to emergency situations which 

may cause environmental impacts. Volkswagen 

Autoeuropa has a private fire-fighting brigade with 

diverse means at its disposal for fire-fighting and 

controlling other risk situations. 

The fire-fighting brigade service is ensured 24 

hours a day during the whole year by elements with 

training in the areas of intervention and prevention. 

These fire-people are capacitated to conduct rescue 

and recovery operations, to deliver first aid and to 

transport the hurt and ill, being able to intervene 

with an ambulance, a heavy auto tank, a light firstaid 

vehicle and a chemical intervention vehicle for 

eventual accidents involving hazardous substances. 

In certain emergency scenarios, there is a risk 

that hazardous substances are able to enter the 

rainwater network (e.g. accident with tanker-truck, 

contaminated waters from fire-fighting, piping 

rupture, etc.). The plant has a cut-off valve at the 

exit of the rainwater network, which allows the 

containment of eventual hazardous substances and 

contaminated waters, up to a volume of 4000m 3 . In 

this way, the aquatic environment is protected. 

Environmental training and awareness 

The training and awareness of workers and suppliers 

on environmental matters is another concern at 

the plant. All the people who exercise activities 

within the company, including the rendering of 

services, receive training on environmental issues 

and emergency response, taught internally through 

awareness sessions. 

Just like the Volkswagen Autoeuropa workers, so 

must the internal suppliers know and respect the 

environmental policy, as well as the basic rules on 

environment and safety, distributed in the form 

of pamphlets in specific meetings or during the 

awareness sessions. 

The existing environmental training includes, 

Organization and cleanliness 

The objective of the organization and cleanliness 

audits is, to ensure in a standardized approach, the 

good operational conditions based on a workplace 

organization philosophy in all production, nonproduction 

and social areas. 

In order to achieve this objective, the audits 

focus themselves on the effective implementation 

and maintenance of the essential ergonomics, 

apart from the previously mentioned obligatory 

awareness sessions, specific courses oriented to 

particular target-groups, namely: 

• Handling and transport of hazardous materials 

• Environmental legislation 

• Environmental management 

• Internal ISO 14001 auditors 

The environmental training and awareness given 

to all individuals who work within Volkswagen 

Autoeuropa helps to elevate the degree of 

internal conscience and responsibility where the 

environment is concerned. 

functionality, accident prevention and waste 

prevention rules. 

This tool provides indirect support to the EMS, 

by evaluating aspects like the correct waste 

segregation, the adequate identification of waste 

bins, and the existence of retention systems 

where applicable, or the labelling and handling of 

hazardous substances and materials. 

21

32,03 

(km/s) 

9,82

422 

4. 


aspects and 

their control

24


Environmental aspects and their control 

Environmental aspects 

Environmental aspects are understood 

to be all the possible forms of 

the company’s interaction with 

the environment, such as all the 

consumptions of natural resources and/ 

or energy, as well as the production 

of liquid or atmospheric effluents, of 

waste, or the emission of noise to the 

surroundings of the plant. 

If they are not adequately 

controlled, these aspects may cause 

environmental impacts. The objective 

of environmental management, 

through its EMS, and the activity of the 

Environmental Control, is to guarantee 

through an adequate management of 

environmental aspects, the prevention 

of the occurrence of significant 

environmental impacts. 

The best way for an organization 

to reduce its environmental impact 

is to, cumulatively, minimise its 

consumption of resources (water, 

natural gas, raw materials) and, by 

minimizing the production of waste, 

reduce the discharge of effluents 

(liquid and atmospheric) and the noise 

emission to the outside. These are the 

principles of eco-efficiency. In this 

chapter we present a summary of the 

Volkswagen Autoeuropa approach in 

respect to the control of environmental 

aspects. 

Water 

Energy 

Raw 

materials 

Wastewaters 

Atmospheric 

emissions 

Waste 

Noise 

Waste 

At Volkswagen Autoeuropa, the 

various types of waste produced 

can be divided in two large groups: 

hazardous and non-hazardous. 

These wastes are grouped according 

to their nature, managed separately, 

stored and shipped to licensed 

operators, with preference being 

given to operators providing 

recovery operations whenever 

technically and economically 

viable. 

Volkswagen Autoeuropa celebrated 

a total waste management contract 

with a dutifully licensed operator, 

which ensures all the internal 

collection, packing and labelling. 

The same operator also coordinates 

all logistics of waste shipment to 

the recovery and disposal operators, 

and organises all documentation 

required by national and European 

applicable legislation. 

It has been the company policy 

to work so as to reduce the waste 

produced and to raise the recovery 

rate of the same. 

25

For an adequate management of all different types of produced waste, 

Volkswagen Autoeuropa has got four dedicated installations: 

A non-hazardous waste segregation 

centre, where the separation and compacting 

of cardboard packages (including office paper), 

plastic film and common industrial waste takes 

place, as well as the separation of wood waste. 

A hazardous waste park, dully covered, 

waterproofed and with a connection to the IWWTP 

(industrial wastewater treatment plant), where all the 

hazardous waste produced in the plant (such as are the 

cases of paint sludge, phosphate sludge, IWWTP sludge, 

waste oils and hydrocarbons, car batteries, glue and sealer 

waste, used solvents, small batteries, fluorescent lamps 

and contaminated packages, among others) are classified, 

conditioned, labelled and prepared for transportation. 

A scrap recovery centre, where waste such as 

damaged vehicle parts and components (metallic 

and non-metallic), glass, copper, aluminium, 

obsolete electrical and electronic equipment, other 

obsolete equipment from the plant, and some waste 

from works and modifications in the plant, are 

segregated and, in certain cases, compacted. 

A baler-house for compacting of metal 

shreds, which are the leftovers from cutting out of 

the various panels that constitute the vehicle body; 

in this plant, the metal shreds are automatically 

pressed and discharged into rail wagons. 

Apart from these dedicated areas, there are numerous 

containers for the adequate waste segregation all over 

the plant, both inside the buildings and close to the 

contractor’s compound. 

The total waste management is a very important part of 

the EMS, having resulted in the definition of a number 

of procedures, instructions and visual aids to assist the 

process, so that all the operations associated with waste 

take place in an integrated way. There is a colour code 

for the various waste containers, and synoptic posters 

were created to illustrate the type of containers and 

their function. 

26



Wastewaters 

Volkswagen Autoeuropa has independent networks 

for rainwater, sanitary and industrial effluents, 

which are respectively identified with the colours: 

blue, brown and purple. The quality of the rainwater 

is assured through the existence of oil separators in 

the parking lots and in various places in the plant, 

and also through the existence of the, previously 

mentioned, cut-off valve at the exit of the rainwater 

network. This way, the discharge of pollutant 

substances into the aquatic environment through 

the rainwater network is avoided. The rainwater, 

which leaves the plant, is conducted into a small 

tributary of the River Tagus (Vala das Sete Fontes). 

The sanitary effluent, originating from toilets, 

locker-rooms and kitchens, is totally treated in the 

municipal WWTP (wastewater treatment plant) 

of Palmela, and later introduced in the same 

hydrological basin mentioned above. 

Finally, the industrial effluents network serves, 

as well as the main production buildings, areas 

such as the contractor’s compound, the waste 

management installations, the cooling water and 

compressor stations, the storage areas for chemical 

products, among others. 

The industrial effluents are all treated at the 

physical-chemical IWWTP (industrial wastewater 

treatment plant) of Volkswagen Autoeuropa through 

technologies that include, among others, the ultrafiltration 

and the flocculation/settling. During 2007, a 

study was initiated with the view of implementing a 

supplementary treatment process based on activated 

carbon, which is foreseen to be running in 2008. 

After treatment at the IWWTP of Volkswagen 

Autoeuropa, the industrial effluents are sent to 

the municipal WWTP of Palmela (for further 

treatment, this time biological). The effluent 

is conducted, via a sewer, from the IWWTP of 

the plant to the municipal WWTP, not allowing 

any contact between the industrial effluents 

and the natural environment. The quality of the 

effluents is controlled on a daily basis by the 

IWWTP operators, and fortnightly by an external 

laboratory. The results are sent to the regional 

environmental authority (CCDR) every semester. 

The water used in the paint booths is treated 

through a specific physical-chemical process, and 

continually re-used. In the end, this process allows 

the re-circulation of water within a closed circuit 

(after removal of the paint overspray, lost during 

the paint process) and, as such, assures Volkswagen 

Autoeuropa relatively low water consumption, 

when compared to most automotive plants. 

27


The paint process used by Volkswagen Autoeuropa 

is essentially water based (exception goes for the 

final clearcoat). This allows one of the lowest 

emission rates in the automotive industry. The 

average emission in the paint process, in the 

previous years, was 33g of volatile organic 

compounds (VOC’s) per m 2 of painted surface, where 

the limit is 60g/m 2 . Even so, the plant is equipped 

to control and reduce its emissions, especially 

those of volatile organic compounds (solvents) to a 

minimum. Associated to the car drying ovens (after 

application of each layer of surface treatment), there 

are incinerators, operating at 750ºC, to completely 

destroy the residual solvent vapours. Three 

incinerators are presently being used. 

Apart from the VOC’s, other pollutants resulting 

from the automotive manufacturing are: particles, 

carbon monoxide and nitrogen oxides. These 

essentially result from thermal processes (boilers). 

The measurements taken reveal that all are emitted 

in rather reduced annual quantities. Therefore, 

the authorities allowed a significant amount of 

emission sources to be monitored only once every 

three years. 

The monitoring of the main pollutants resulting 

form the incinerators, boilers and exhaust systems 

is undertaken by an external entity every semester, 

and the obtained results are communicated to 

CCDR. Although Volkswagen Autoeuropa is not 

covered by the European legislation on greenhouse 

gas emission allowance trading, numerous internal 

energy saving measures were implemented, thus 

contribution to a CO 2 

emission reduction. 

Noise 

Volkswagen Autoeuropa is situated in an 

industrial area. So as to evaluate and control the 

meaningfulness of the environmental noise levels, 

measurements were taken every two years, and there 

are no external complaints. The emission levels are 

not high for the type of zone and the presence of 

eventual discomfort receptors is relatively distant. 

Given the entry into force of a new legal frame 

on noise, a new monitoring campaign was carried 

out and once more the legal compliance with 

the environmental noise emission levels was 

demonstrated. 

Water consumption 

Volkswagen Autoeuropa is supplied by the public 

network of the Palmela Municipality and by its 5 

own boreholes. Of the 5 boreholes, all licensed, 2 

are used for watering of the landscaping areas and 

the rest for industrial uses. In 2007, the irrigation 

patterns and irrigation hours were reprogrammed, 

enabling some water usage reduction. 

There are 2 independent distribution networks in 

the plant: one for industrial use and fire-fighting, 

and another just for human consumption. 

28



Natural gas 

consumption 

Natural gas is transported via pipelines, up to 

Volkswagen Autoeuropa, avoiding the emissions and 

risks associated with road transport and unloading, 

which were present when the plant was supplied 

with liquid propane. The natural gas extraction and 

transport process generates very low emissions, 

contrary to the case of liquefied petroleum gases. 

It is the cleanest fossil fuel (essentially methane), 

does not emit sulphur or nitrogen oxides, and does 

not produce ashes or particle emissions. The plant 

was conceived since the project phase to use this 

type of fuel, but it only started using natural gas 

when it became available in Portugal (Volkswagen 

Autoeuropa was the first large consumer of this 

energy source on a national scale). This fuel has also 

got advantages on the economical side. 

Soil protection 

The pipelines transporting fluids likely to cause 

environmental contamination were installed 

above the ground, whenever possible. The storage 

tanks existing above ground have bunded walls. 

The underground tanks have double wall, with 

leak-detection systems. In the tank-farm area for 

production fluids (diesel, gasoline, oils, windscreen 

cleaner and engine coolant), the rainwater network 

is protected by a cut-valve that automatically shuts 

before unloading operations, as soon as the tankertruck 

connects to the piping. 

Energy 

consumption 

Volkswagen Autoeuropa receives electrical energy 

at very high voltage (150kV), which is then 

transformed in its own electrical substation and 

distributed at a medium voltage (20kV). The main 

electrical energy consumers are the production 

process, air conditioning and ventilation of 

industrial areas, and the respective lighting. 

The plant has a computerized energy management 

system, which allows the management and 

monitoring of consumptions and issues alerts in 

case of high instant consumption; it can also acting 

in emergency cases, not allowing the contracted 

power factor to be exceeded. 

The areas, both for the storage of waste and for the 

handling of hazardous products, are impervious. As 

backup equipment, there are also: 

• spill-kits in the whole plant, to be used in case 

of leaks; 

• a vehicle for chemical emergencies, equipped 

to control leakages and to clean spillage areas 

involving hazardous substances (available in the 

fire-fighting building, as referred before). 

Materials approval 

The materials used in Volkswagen Autoeuropa are 

previously submitted to an internal approval process. 

We are referring to products that may be hazardous 

to people’s health or the environment, such as certain 

oils, paints, enamels, waxes, sealers, cleaning and 

industrial maintenance products, laboratory reactants 

and other chemicals. The objective of this approval is 

to prevent that high-risk substances or preparations 

enter the plant. To internally approve a new material, 

the safety data sheet is analysed by a multifunctional 

team, in which industrial hygiene, work medicine, 

industrial safety, fire prevention, environmental 

control and the user areas take part. When high-risk 

materials are identified, they are rejected for internal 

use in the plant. In 2007, it was decided to invest on 

an electronic workflow system to support the approval 

process, by enabling a faster release and a proper way 

to keep the information on used materials. 

29

30



Transportation 

One of the pollution sources indirectly related 

to Volkswagen Autoeuropa results both from 

the transport of the components up to the plant, 

and from product shipment (finished vehicles). 

In this field, there has also been an attempt to 

select the means of transportation, so as to reduce 

environmental impacts. Since the start-up of the 

plant in 1995, the expedition of the majority of 

the production is made by train up to the Setúbal 

harbour. This means of transportation is also used 

to ship to steel foundries a waste produced in 

great quantities: the baled metal shreds, resulting 

from the cutting out of car panels. In 2007, 1013 

railway wagons with baled scrap left Volkswagen 

Autoeuropa, each one carrying about 22 tons in 

average, 

The environmental advantages associated to rail 

transportation are the low atmospheric emission 

levels, as well as lesser energy consumption (per 

transported ton). 

Influence over suppliers 

Environmentally speaking, Volkswagen Autoeuropa 

considers the activity of its direct suppliers as 

an extension of its own activity. In this way, it 

established the environmental certification as an 

objective for the Industrial Park suppliers and for 

some nearby suppliers, for which this approach 

makes sense. More recently, it broadened its range 

to some contracted maintenance service suppliers. 

A process was implemented for the influencing 

and follow-up of these companies, which involves 

periodic visits that result in an evaluation. This 

work is developed in conjunction by Environmental 

Control and Logistics, since the later is the main 

communication link with the suppliers. Presently, 

some Volkswagen Autoeuropa suppliers that already 

achieved Environmental Certification have started 

to influence their own suppliers in the same sense. 

This process aims to contribute, over a long term, to 

a reinforcement of sustainable development of the 

region and the country. 

Suppliers with 

environmental 

certification 

in 2007 

Visteon 

Benteler 

Faurecia 

Tenneco 

Rieter 

for components 

PPG 

Vanpro 

Continental-Lemmerz 

SAS 

Lear 

Webasto 

for services 

Wheels 

Palmetal 

Isporeco 

Acciona 

Teleflora 

Sodexho 

Océ Portugal 

31

997 

002 

704 

(unid./h) 

Nm 3 1.717

0,2203 

5. 


objectives 

and results

Objectives 

and results 2007 

Estado 

Maintain and renew the ISO14001:2004 certification. 

Meet or go beyond environmental legal and other requirements. 

Attained 

Attained 

Promote environmental the efforts of Volkswagen Autoeuropa in schools 

or universities, through presentations in their own facilities or study visits; 

Publish an updated Environmental Indicators brochure and distribute it 

on the intranet/internet. 

Conclude the improvements in the waste area near the contractors park. 

Attained 

Attained in 

2008 

Ongoing 

Implement an alternative overbody transportation protection to replace 

the current solvent-based wax application. 

Attained 

Continually monitor the energy consumption and implement several 

activities in order to reduce electricity, natural gas and compressed air 

consumption. 

Reduce sealer consumption by 1%/car (Eos). 

Attained 

Attained 

Reduce steel consumption by 4,2 kg/car (MPV) and 4,4 kg/car (Eos), 

in comparison with the year 2006. 

Attained 

Influence contractors activities in order to stimulate their adoption of 

environmental management systems and to improve their environmental 

performance. 

Ongoing 

Reduce basecoat consumption by 0,5 l/car and SO25 solvent 

consumption by 1,8 l/car, in comparison with the year 2006. 

Eliminate dismissible paper towels and paper cups in the canteens. 

Apply to the Eos assembly line a recovery procedure to the plastic parts 

that result from this process. 

Attained 

Attained 

Attained in 

2008 

34


Environmental objectives and results 

Some examples 

of implemented programmes 

Stamping 

In 2007, the Stamping Area 

introduced improvements in the 

manufacturing process, leading 

to reductions in steel consumption 

of 4,4 kg per each produced Eos 

body and 4,2 kg per each MPV 

body. This corresponded to a 

saving of 323 tonnes of steel by the 

end of the year. 

Paulo Rocha, 

responsible for the project 

35

Body 

In 2007, the Body Area 

introduced improvements in the 

process, leading to a sealer 

consumption reduction of 1% 

per each produced Eos body, 

when compared to 2006. This 

corresponded to a saving of 

approximately 1,4 tonnes of 

sealer. 

Paulo Oliveira, 

Body ISO14001 Coordinator 

36



Paint 

In 2007, the Paint Area invested 

1 257 152€ in a batch colour 

select store to improve the batch 

painting. This improvement led to 

a consumption reduction of 1,61 

litres of paint and 3,13 litres of 

solvent per car, thus exceeding 

the initial forecast. 

Mário Luís, 

Paint ISO14001 Coordinator 

37

Trim & 

Assembly 

In 2007, the Trim & Assembly 

Area implemented the selective 

recovery and recycling of small 

plastic parts removed from vehicle 

components in the Eos line. These 

small parts were previously sent to 

landfill, and since the beginning of 

this project more than 80 tonnes 

of plastic were already sent to 

recycling. 

Sofia Silva, 

Trim & Assembly ISO14001 Coordinator 

38



Human 

Resources 

In 2007, the Human Resources 

Area eliminated the use of paper 

cups in the canteens replacing 

them with reusable ones, and 

eliminated the use of paper 

towels in the canteen trays. 

These improvements prevent the 

yearly dumping into landfill of 

approximately 660 000 cups and 

7,2 tonnes of paper towels. 

Maria Gameiro, 

Human Resources ISO14001 

Coordinator 

39

40



Objectives 

for 2008 

Maintain the ISO14001 certification 

according to ISO14001:2004. 

Promote environmental the efforts 

of Volkswagen Autoeuropa in 

schools or universities, through 

study visits and/or presentations in 

their own facilities. 

Publish an Environmental Report 

2007 and distribute it in the intranet 

and internet. 

Define a new landscaping concept 

that is less water-demanding and 

initiate a phased replacement. 

Meet or, if possible, exceed the 

legal and other requirements that 

are applicable to Autoeuropa. 

After the start-of-production, 

monitor the copper welding tips 

consumption per car in the Scirocco 

line and reduce 1% in 2009 relative 

to 2008. 

Reduce the steel consumption by 0,5 

kg/car in the Eos line, relative to 

2007. 

Influence the activities of the 

Suppliers Park in order to stimulate 

their adoption of environmental 

management systems and to 

improve their environmental 

performance. 

Conduct a technical study, aiming 

the eventual future reduction of 

the burning temperature in the 

incinerators. 

Conduct a feasibility study on the 

use of alternative fuels and/or on 

the transportation means for the 

incoming parts. 

Implement a collection-at-the-source 

scheme for the filling equipment 

start-up purges and to the waste 

fluids from the car-repair stations. 

41

1.233,03 

407,23 

(t/m 2 ) 

668 

CO 2 

3,10

42,306 

6. 


indicators

Vehicle production 

120 000 

100 000 

80 000 

60 000 

40 000 

20 000 

2003 2004 2005 2006 2007 

The growing trend of the production 

volume, already visible in 2006, 

maintained itself during 2007 and by 

the year end, the total volume was 

already comparable to 2004. Volkswagen 

Autoeuropa maintains its continuous 

efforts to produce new models for the 

Volkswagen Group and holds interesting 

perspectives to deliver future higher 

volumes. 

44


Environmental indicators 

Consumption of natural 

resources and energy 

Total water consumption (m 3 ) per type of use 

Human 

consumption 

Borehole 

for irrigation 

Borehole for 

Industrial use 

700 000 

600 000 

500 000 

400 000 

300 000 

200 000 

100 000 

2003 

2004 

2005 

2006 

2007 

Specific industrial water consumption (m 3 /vehicle) 

5 

4 

3 

2 

1 

2003 

2004 

2005 

2006 

2007 

Total (m 3 ) and specific industrial water consumption (m 3 /vehicle) 

Total 

consumption 

(m 3 ) 

400 000 

375 000 

6 

5 

Specific 

consumption 

(m 3 /vehicle) 

350 000 

325 000 

300 000 

4 

3 

2 

275 000 

1 

2003 

2004 

2005 

2006 

2007 

45

Total electricity consumption (MWh) 

120 000 

100 000 

80 000 

60 000 

40 000 

20 000 

2003 

2004 

2005 

2006 

2007 

Specific electricity consumption (KWh/vehicle) 

1 200 

1 000 

800 

600 

400 

200 

2003 

2004 

2005 

2006 

2007 

Total (MWh) and specific electricity consumption (KWh/vehicle) 

Total 

consumption 

(MWh) 

104 000 

102 000 

1 600 

1 400 

Specific 

consumption 

(KWh/vehicle) 

100 000 

98 000 

1 200 

1 000 

96 000 

800 

94 000 

92 000 

600 

400 

2003 2004 2005 2006 2007 

46



Total natural gas consumption (Nm 3 ) 

8 000 000 

6 000 000 

4 000 000 

2 000 000 

2003 

2004 

2005 

2006 

2007 

Specific natural gas consumption (Nm 3 /vehicle) 

100 

80 

60 

40 

20 

2003 

2004 

2005 

2006 

2007 

Total (Nm 3 ) and specific natural gas consumption (Nm 3 /vehicle) 

Total 

consumption 

(Nm 3 ) 

8 000 000 

7 500 000 

120 

100 

Specific 

consumption 

(Nm 3 /vehicle) 

7 000 000 

6 500 000 

6 000 000 

80 

60 

40 

5 500 000 

20 

2003 2004 2005 2006 2007 

47


VOC emissions (g/m 2 ) 

70 

60 

legal limit 

50 

40 

30 

20 

10 

2003 

2004 

2005 

2006 

2007 

Direct CO 2 

emissions (ton) 

20 000 

15 000 

10 000 

5 000 

2003 

2004 

2005 

2006 

2007 

48



Waste production (ton) 

Destination 

2003 

2004 

2005 

2006 

2007 

Non-hazardous wastes 

recovery 

elimination 

1 174 

1 230 

1 858 

943 

1 670 

860 

1 140 

1 046 

1 122 

1 021 

Hazardous wastes 

recovery 

elimination 

1 140 

1 950 

438 

1 016 

605 

982 

702 

1 093 

554 

531 

Wastes which volume is independent 

from production 

recovery 

elimination 

13 

236 

10 

426 

16 

448 

21 

427 

35 

519 

Metallic wastes (ferrous and non-ferrous) 

recovery 

37 408 

35 597 

31 279 

26 394 

25 319 

Wastewaters 

Average concentration of the most relevant pollutants in our 

final effluent before municipal biological treatment (mg/l) 

YEAR 

Al 

Mn 

As 

Cr VI 

Ni 

CN 

Mineral 

oils 

Zn 

Pb 

Cd 

Cu 

2003 

2,53 

0,72 

0,003 

n.d. 

0,86 

n.d. 

8,36 

(a) 

n.d. 

n.d. 

n.d. 

2004 

1,36 

0,77 

0,008 

n.d. 

0,52 

n.d. 

8,73 

0,33 

n.d. 

n.d. 

n.d. 

2005 

0,86 

0,96 

0,003 

n.d. 

0,48 

0,019 

7,67 

0,37 

n.d. 

n.d. 

0,08 

2006 

11,72 

1,16 

0,004 

n.d. 

0,73 

0,011 

2,07 

1,67 

n.d. 

n.d. 

n.d. 

2007 

1,25 

0,41 

n.d. 

n.d. 

0,60 

0,018 

3,09 

0,19 

n.d. 

n.d. 

n.d. 

Guiding 

value 

10 

2 

1 

0,1 

2 

0,5 

15 

- 

1 

0,2 

1 

n.d. - not detected 

(a) - monitoring of this parameter started only in 2004 

49

50



Environmental noise 

By the 

environmental 

exposure level 

Measuring 

point 

1 

Environmental noise level 

Lden 

Ln 

63,2 54,9 

Background noise level 

Lden 

Ln 

61,4 54,6 

2 

56,6 

50,4 

56,1 

50,1 

3 

54,4 

48,3 

52 

45,8 

4 

52,5 

45,6 

51 

44,9 

Legal limit dB(A) 

65 

55 

65 

55 

By the level differences 

Measuring 

point 

Day period 

Ld ra Ld rr Ld ra - Ld rr 

Evening period 

Le ra Le rr Le ra - Le rr 

Night period 

Ln ra Ln rr Ln ra - Ln rr 

1 

60,20 

57,95 

2,2 

56,76 

56,55 

0,2 

56,53 

54,60 

1,9 

2 

51,32 

49,72 

1,6 

50,46 

49,26 

1,2 

50,35 

50,06 

0,3 

3 

47,86 

46,69 

1,2 

49,01 

45,41 

3,6 

48,26 

45,76 

2,5 

4 

50,02 

46,17 

3,9 

46,19 

43,23 

3,0 

45,59 

44,85 

0,7 

Legal limit dB(A) 

- 

- 

5 

- 

- 

4 

- 

- 

3 

Despite the fact Volkswagen Autoeuropa is an industrial site where the legal limits don’t apply, they have to 

be respected in the vicinity of potential nearby inhabitants in the surrounding areas. 

Lden Day-evening-night noise indicator for overall 

annoyance over a 24 hours period 

Ld 

Day noise indicator for annoyance during the 

day period 

4 

3 

Le 

Evening noise indicator for annoyance during 

the evening period 

2 

Ln 

Night noise indicator for sleep disturbance 

ra 

rr 

Environmental noise level: noise measured when 

the activity under study is running 

Background noise level: noise measured when 

the activity under study is stopped 


1 

Measuring points 

A2 

51

2,98 

(Kw/h) 

1,33 

H 2 

0 501 

0,028

42,306 

7. 


costs and 

investments

54


Environmental costs and investments 

Running costs (€) 

Waste management 

Total costs with the IWWTP 

Green Dot Tax and audit to the annual statement 

Waste segregation area for the contractor’s compound 

External audits 

Atmospheric emissions monitoring 

Environmental Indicators brochure 

Environmental noise measurement 

Legislation providing service 

Boreholes license renewal 

TOTAL 

1 425 483 

136 666 

43 494 

25 981 

11 788 

7 459 

2 987 

1 766 

303 

163 

1 656 090 

Investments (€) 

Batch colour select store 

Energy saving actions 

IWWTP improvements 

Improve access to chimneys 

TOTAL 

1 257 152 

51 050 

3 112 

1 622 

1 312 936 

55

Credits and contacts 

1 st Edition 

Volkswagen Autoeuropa, Automóveis Lda. 

Planning, Environment and Infrastructures 

Date 

July 2008 

Technical direction 

Paulo Baptista 

Manuel Ribeiro 

Photographs 


dodesign designers associados 

Design 

dodesign - designers associados 

Pta. Amadeu Sousa Cardoso, nº 2 - loja 1 

2910-737 Setúbal 

Tel.: +351 265 537 305 

Fax: +351 265 537 306 

www.dodesign.pt 

Printing 

Gráfica, Lda. 

Praceta José Sebastião e Silva, lote 20 

Parque Industrial do Seixal 

2840-072 Paio Pires 

Tel.: +351 212 110 520 

Fax: +351 212 110 529 

Output 

50 copies (english version) 

Legal register nr. 214884/04 

(according to decree-law nr 74/82 of March 3 rd ) 

This Environmental Report 

can be ordered from: 


Public Affairs Department 

Quinta da Marquesa 

2951-510 Quinta do Anjo 

Portugal 

www.autoeuropa.pt 

Tel.: +351 21 2112900 / 3248 / 2552 

Fax: +351 21 2112992

Printed on recycled paper 

© Volkswagen Autoeuropa 

Quinta da Marquesa 

2951-510 Quinta do Anjo 

Portugal 

Environmental Report, July 2008

Environmental Report - Volkswagen Autoeuropa

You also want an ePaper? Increase the reach of your titles

Delete template?

Save as template?