Overall, company emissions went up 32% in 2010 compared to 2009 due to higher production, a change in product mix to a higher percentage of dyed t-shirts which utilize twice the water and energy, and a whopping 80% increase in outgoing deliveries, as the result of expanded complete scope two reporting in 2010 for delivery emissions. This increase was partially offset by a 9% decrease in emissions from premises energy consumption. Smaller victories included a 31% decrease in emissions from on-site vehicle usage. We recently also calculated our water footprint and the life cycle water footprint of some of our basic t-shirts and discovered that the greatest impact comes not from our textile manufacturing but from the agricultural production stage of cotton. Learn more by clicking on the water drop icon.
We believe that 2010 represents a more normalized year compared to 2009, when we reduced production in response to the economic downturn. Nevertheless, on a per unit basis, we have shown improvement when comparing white or dyed -shirt produced in 2010 against its comparable t-shirt produced in 2009.
We're also pleased to report that in 2010, we reduced the total amount of landfill waste we generated by nearly 25% due to greater recycling efforts in all facilities, even in a year that saw more than a 36% increase in production. Surpassing last year's target of a 5% reduction in waste!
Anvil Organizational Assessment
Our greenhouse gas (GHG) emission shows the total amount of energy used in Anvil operations. We used a significant amount of real data from facilities this year that previously were estimates.
Company emissions went up 32% in 2010 compared to 2009 due to higher production, a change in product mix to a higher percentage of dyed t-shirts (which uses more energy in production) and an increase in outgoing deliveries, which was the result of more accurate reporting in 2010 for delivery emissions. See detailed GHG Emissions here.
Our primary source of direct energy continues to be Bunker C oil, used to power the on-site boilers that produce steam for dyeing and finishing fabric at our Honduras textile plant. In 2010, we saw a 64% increase in Bunker C, driven by the year's production growth and the increased percentage of dyed fabric over white. Dyed fabric uses twice as much steam as white fabric.
Meanwhile, electricity remains our primary source of indirect energy at our facilities. However, we remain committed to increasing our use of bio-mass which we did by 10% in 2010 (saving an estimated 60,460 gallons of oil).
Conservation efforts under our AnvilSustainableManufacturing (ASM) program, which is a comprehensive company-wide initiative that incorporates Anvil's sustainability policies and goals into daily decision making, yielded savings in a number of areas, including the following examples:
- Energy conservation system for fabric dryer also yielded productivity gain of 5%
Energy, Water &
- Enhancements to Wastewater Heat Recovery System allowed us to save nearly 70,000 gallons of bunker oil
- 10% reduction in water consumption from dye recipe change & reuse of cooling water = estimated 60,000,000 gallons saved
- Steam cost savings from installation of automatic moisture controls saved more than $39,000 on steam, which is equivalent to 3,300,000 lbs. of steam
Cut & Sew
- Electricity conservation resulted in a 6% reduction in electricity
- We reduced the total amount of landfill waste by nearly 25% due to greater recycling efforts in all facilities, even in a year that saw more than a 35% increase in production. Surpassing last year's target of a 5% reduction in waste!
In 2010, our production grew by 36%, driven mostly by an increase in dyed t-shirts. This also drove a 40% increase in the amount of dyes and chemicals we used, while our overall increase in production drove a 41% increase in yarn usage. Although our commitment to use environmentally-sustainable fibers remains strong, our overall usage of recycled inputs declined due to a number of factors, including challenges in fiber sourcing.
While we do not report the percentage of organic and transitional cotton yarn used per year for competitive reasons, we have been ranked by the Textile Exchange as having the 7th largest organic program in the world in 2010 and consecutively ranked 6th for 2008 and 2009. Robust sales of Anvil's private label organic and organic blends to several of our customers in the top 10 ranking was the main reason for the AnvilOrganic™ to rank 7th in 2010.
Anvil's overall usage of water in the production of its products increased due to higher production and a higher ratio of dyed to bleached t-shirts produced in 2010, which increase was partially offset by process improvements, including increased use of recycled water. We are currently finding new ways to use and reuse water in the production process and cutting water-intensive steps, such as avoiding a rinse cycle.
While we are pleased with our progress in reducing production water in 2010, we recently discovered through a water footprint that the impact of our production water is negligible in our overall water footprint compared to the water used in cotton agriculture. The same conclusion was reached in our product life cycle water study of our basic Anvil® cotton t-shirt.
Transportation, Business Travel
Due to increased production, we saw an 80% increase in emissions from the transportation of our goods in 2010.
In 2010, we completed a third party assessment of our logistics which identified several areas for potential efficiencies. One example is that we have increased our shipments through the port of Wilmington, North Carolina to reduce trucking mileage compared to shipments coming into the Florida ports.
Also, we have expanded our warehouse space in Central America near our factories in order to ship direct to some large customers and avoid the environmental impact of shipping goods through our South Carolina distribution center.
Finally, commuting increased in 2010 by 16% from 2009 due to increased bus and motor bike travel as a direct result of an increased workforce.
Goal 1 -
Reduce Energy Per Unit Produced by
20% by 2020
Goal 2 -
Reduce Water Per Unit Produced by
20% by 2020
Goal 3 -
Achieve Zero Landfilled Waste Stream by fiscal by 2020
Goal 4 -
Adopt ASM throughout the organization by
the end 2013