This document describes the application of the ecoPROSYS methodology to assess the eco-efficiency of a medium density fiberboard finishing line. The methodology integrates environmental performance evaluation, life cycle assessment, and value modelling to generate eco-efficiency profiles. It was applied to map the finishing line processes, assess environmental impacts and costs, and identify opportunities to improve eco-efficiency. The results showed the environmental influence and value indicators for each process, as well as an overall eco-efficiency indicator. The methodology allows simulation of alternatives to support continuous improvement decisions for production systems.

1. 22nd – 24th May 2016
Organized by: In cooperation with: Sponsored by:
ecoPROSYS: An eco-efficiency framework applied
to a medium density fiberboard finishing line
A.J. Baptista, E.J. Lourenço, J.P. Pereira, F. Cunha, E.J. Silva, P. Peças
António J Baptista
abaptista@inegi.up.pt

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AGENDA
 Introduction
 ecoPROSYS methodology description
 Case study description and results
 Conclusions and remarks

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Introduction
Objectives
• Identification and evaluation of unit processes and production systems for its eco-
efficiency performance
• Connection of the eco efficiency principles with the appropriate environmental aspect
• Identification and quantification of the variable(s) or key aspect(s) that affect eco-
efficiency performance;
• Life Cycle Assessment and Life Cycle Cost Assessment integration
• Identification of the significant environmental aspects;
• Definition of eco-efficiency improvement strategies;
• Quantification of eco efficiency performance variations / evolution
Eco-Efficiency Integrated Methodology for Production Systems: ecoPROSYS©

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Introduction
ecoPROSYS© is a new eco-efficiency approach that comprehends the continuous
joint developments of a team of entities integrated in the PRODUTECH Cluster

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Reduce material
intensity
Reduce energy
intensity
Reduce dispersion
of toxic substances
Enhance
recyclability
Maximize use of
renewable resources
Extend product
durability
Increase service
intensity
7
Principles
Eco-Efficiency
Product, process or service value
Environmental influence
=
Introduction

6. ecoPROSYS methodology description
Page 6
Eco-Efficiency Profile
Process Mapping
Goal and Scope Definition
Determination of system boundaries
Identification and sequence of stages
Definition of functional unit
Definition of system model (flows)
Process
Mapping

7. ecoPROSYS methodology description
Page 7
Eco-Efficiency Profile
Process
Mapping
• Environmental Performance Assessment (EPA)
• Life Cycle Assessment (LCA)
• Value Modelling
ecoPROSYS Pillars:

8. ecoPROSYS methodology description
Page 8
No Eco-efficiencyPrinciple
Low
intensity
Intense
High
intensity
P1 Reduce material intensity 1 3 5
P2 Reduce energy intensity 1 3 5
P3 Reduce dispersion of toxic substances 1 3 5
P4 Enhance recyclability 1 3 5
P5 Maximizeuse of renewable resources 1 3 5
P6 Extend product durability 1 3 5
P7 Increase service intensity 1 3 5
EPA – Input Flows
Aspect Group Aspect P1 P2 P3 P4 P5 P6 P7 F S R E
Materials Paint 5 1 3 3 1 5 1 5 5 25 3
Materials Hardener 5 1 3 3 1 5 1 5 5 25 3
Energy Electricity 1 5 3 1 3 1 1 5 5 25 5
EPA – Output Flows
Aspect Group Aspect P1 P2 P3 P4 P5 P6 P7 F S R E
Residues
Paint
Packaging
3 1 5 5 1 1 1 3 5 15 3
Residues
Hardener
Packaging
3 1 5 5 1 1 1 3 5 15 3
Air emissions VOC 3 1 5 5 1 1 1 3 5 15 3
Environmental intensity and
significance Parameterization
F = Frequency
S = Severity
R = Risk = F * S
E = Extension
ISO14001
Environmental Performance Assessment

9. ecoPROSYS methodology description
Page 9
No Eco-efficiencyPrinciple
Low
intensity
Intense
High
intensity
P1 Reduce materialintensity 1 3 5
P2 Reduce energy intensity 1 3 5
P3 Reduce dispersion of toxic substances 1 3 5
P4 Enhance recyclability 1 3 5
P5 Maximizeuse of renewable resources 1 3 5
P6 Extend product durability 1 3 5
P7 Increase service intensity 1 3 5
Significance = P * R * E
Significance Analysis – Input flows
Aspect Group Aspect P1 P2 P3 P4 P5 P6 P7
Materials Paint HS LS S S LS HS LS
Materials Hardener HS LS S S LS HS LS
Energy Electricity LS HS HS LS HS LS LS
Significance Analysis – Output flows
Aspect Group Aspect P1 P2 P3 P4 P5 P6 P7
Residues Paint Packaging LS LS S S LS LS LS
Residues
Hardener
Packaging
LS LS S S LS LS LS
Air emissions VOC LS LS S S LS LS LS
Environmental intensity and
significance Parameterization
Environmental Performance Assessment

10. ecoPROSYS methodology description
Page 10
Eco-Efficiency Profile
Process
Mapping • Environmental Performance Assessment (EPA)
• Life Cycle Assessment (LCA)
• Value Modelling
ecoPROSYS Pillars:

11. ecoPROSYS methodology description
Page 11
Free available databases
• ELCD
• APME - Industry data 2.0
• LCA Food DK
• US LCI
• GREET
• ALCAS
• SPINE@CPM
• IISI
• GTGLCI
• GEMIS
• …
Tool
Database
Input
Categories
Impact 2002+
Impact
Categories
Damage
Categories
Life Cycle Assessment (LCA)

12. ecoPROSYS methodology description
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Characterisation
Tool
Database
Output
Input
Categories
Impact 2002+
LCA Results
Environmental
Influence
Impact 2002+
Input by user
Impact
Categories
Damage
Categories
Calculation
Type of material
Type of energy
Type of resource
Type of residue
Type of emission
Amount
Amount
Amount
Amount
Amount
Process
Mapping

13. ecoPROSYS methodology description
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Eco-Efficiency Profile
Process
Mapping • Environmental Performance Assessment (EPA)
• Life Cycle Assessment (LCA)
• Value Modelling
ecoPROSYS Pillars:

14. ecoPROSYS methodology description
Page 14
Materials
Energy
Resources
Residues
Equipment
Labour
Standard
accounting
system
indicators
Financial investments
Sales
Operating subsidies
Supplies and external services
Labour costs
…
GAV
EBITDA
Gross production
value
…
Value Modelling

15. ecoPROSYS methodology description
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Eco-Efficiency Profile
Significant
environmental
aspects
Life cycle
assessment
Value
modelling
Environmental
performance
assessment
Process
Mapping
Environmental
influence
(KEPIs)
Value
indicators
Eco-Efficiency Profile

16. ecoPROSYS methodology description
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ecoPROSYS Profiles
Environmental Profile
Indicator Value
Materials and Raw Materials 780 kg
Total Energy 10.000 kWh
Water consumption 2,27E-02 m3
Residues (total) 29 kg
GHG Emissions 6580 kg CO2 eq.
Acidification 65 kg SO2 eq.
Electricity 0,49 Pts
Materials and Raw Materials 0,71 Pts
Residues incineration 0,0021 Pts
Environmental Influence (Total) 2,41 Pts
Value Profile
Indicator Valor
EBITDA 150,00 €
GAV 400,00 €
Sales 500,00 €
Production time 475 hours
Product Durability 40 years
Eco-eficiency Profile
Eco-eficiency Principle Environmentl Aspect
Ratio: GAV
IA
P1 - Reduce material intensity Materials Paint 740,59
P2 - Reduce energy intensity Energy Diesel 313,79
P2 - Reduce energy intensity Energy Electricity 805,60
P3 - Reduce dispersion of toxic substances Air emissions VOCs 33256,84
Eco-efficiency (Total) 165,98

17. ecoPROSYS methodology description
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Eco-Efficiency Profile
Significant
environmental
aspects
Life cycle
assessment
Value
modelling
Environmental
performance
assessment
Process
Mapping
Environmental
influence
(KEPIs)
Value
indicators
Eco-Efficiency profile
Goals

18. ecoPROSYS methodology description
Page 18
Nº Eco-efficiencyPrinciples Goal
P1 Reduce materialintensity 0%
P2 Reduce energy intensity 10%
P3 Reduce dispersion of toxic substances 0%
P4 Enhance recyclability 0%
P5 Maximizeuse of renewable resources 0%
P6 Extend product durability 0%
P7 Increase service intensity 0%
Energy – Current Scenario
Type of Energy Quantity (kWh/year) Cost (€/year)
Electricity 2500 200
Diesel 7500 900
Energy – Alternative Scenario
Type of Energy Quantity (kWh/year) Cost (€/year)
Electricity 2250 180
Diesel 6750 810
Indicator Current scenario Alternative scenario
Energy consumption 10.000 kWh 9.000 kWh
Energy cost 1.100 € 990 €
GHG Emission 6580 kg CO2 eq. 5800 kg CO2 eq.
Acidification 65 kg SO2 eq. 58,62 kg SO2 eq.
Electricity 0,49 Pts 0,441 Pts
Environmental Influence (total) 2,41 Pts 2,35 Pts
Eco-efficiency Ratio: VAB
IA
165,98 170,21

19. ecoPROSYS methodology description
Page 19
Eco-Efficiency Profile
Significant
environmental
aspects
Life cycle
assessment
Value
modelling
Environmental
performance
assessment
Process
Mapping
Environmental
influence
(KEPIs)
Value
indicators
Eco-Efficiency profile
Goals
Continuous
Improvement

20. ecoPROSYS methodology description
Page 20
Eco-Efficiency Profile
Significant
environmental
aspects
Life cycle
assessment
Value
modelling
Environmental
performance
assessment
Process
Mapping
Environmental
influence
(KEPIs)
Value
indicators
Eco-Efficiency profile
Goals
Simulation of alternatives and sensitivity analysis
Material and
Energy Flow
Analysis
LCC
approach

21. ecoPROSYS methodology description
Page 21
Eco-
efficiency
Life Cycle Impact
Assessment
Scope & Data
Collection
Cost & Value
Assessment
Environmental
Performance Evaluation
KEPI
Eco-efficiency
Indicators
Cost & Value
Data
Environmental
Profile
Eco-efficiency
Profile Value Profile
ContinuousImprovement
Indicators
Profile

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Case study description and results
Plywood boards finishing line description
Unit Process (Stages) Description
Feeding table Supply the conveyer with boards (automatically)
Calibrating
Consist in calibrating the board's thickness using coarse and medium
sand paper
Sanding
Consist in sanding the MDF boards to obtain a smooth finish and
guarantee the specification thickness
Cutting
The cutting process consists of two steps, vertical cutting and
longitudinal cutting, during these steps the MDF boards are also
calibrated in terms of width and length
Stacking
During this unit process the MDF boards, already cut, are stacked, and
the protection board is placed on the top
Packing
This unit process is carried out by placing cardboard and the base
studs, finally the strapping PET tape placed

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Case study description and results
Plywood boards finishing line description
Description Amount (per m3) Unit
Materials MDF supplied into the finishing line 900.620 kg
Auxiliary Materials
Sandpaper 0.288 m2
Cardboard package 0.649 kg
Protective MDF board 32.420 kg
Stud (base protection) 8.230 kg
PVC strapping tape 0.240 kg
Energy
Diesel (fork lift) 0.252 kg
Electric 43.715 kWh
Water Cooling water 100 Litres
Air Emissions CO2 emissions (forklift) 0.670 kg
Wastewater Cooling water 100 Litres
Residues
Wood trimmings and dust 150.620 kg
Sand paper 0.2881 m2

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Case study description and results
Plywood boards finishing line: Results
Environmental influence of material and energy (Single score)
Environmental influence of each unit process per damage category (Single score)

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Case study description and results
Plywood boards finishing line: Results
Eco-efficiency profile - Unit processes
Unit processes (2) Normalized
Impacts (Pt)
Normalized
costs (€)
Eco-efficiency
indicators
Feeding table 0.03 0.02 6.51E-01
Calibrating 0.70 0.22 3.20E-01
Sanding 0.91 0.28 3.04E-01
Cutting 0.02 0.06 3.26E+00
Stacking 1.00 0.03 2.87E-02
Packing 0.48 1.00 2.11E+00
Overall eco-efficiency indicator(3) 2,05E+03
(2) - Unit Process Production Cost/Unit Process Environmental influence
(3) - GVA/Environmental influence

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Case study description and results
Plywood boards finishing line: Results
Environmental Profile
Energy and materials - Environmental Influence
Material consumed 6.53E-03 Pt
Electrical energy consumed 8.26E-03 Pt
Diesel consumed 1.85E-04 Pt
Water used 8.53E-05 Pt
Global warming 4.07E+01 kg CO2 eq
Aquatic acidification 2.85E-01 kg SO2 eq
Ozone layer depletion 2.75E-06 kg CFC-11 eq
EBITDA 14.80 €/m3
GVA 30.82 €/m3
Sales 237.80 €/m3
Production cost 12.15 €/m3
Value profile

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Case study description and results
Plywood boards finishing line: Results
Eco-efficiency plot for MDF finishing line production system
(bubble area is proportional to environmental impact - Pt)

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Conclusions and remarks
 ecoPROSYS© is a flexible standard-based methodology to assess the eco-
efficiency performance of production systems
 Integrates Environmental Performance Evaluation (EPA) with Environmental
Impact and Cost/Value assessment models through a life cycle prespective
(LCA and LCC)
 Generates a comprehensive set of simple and intuitive indicators (KPI and
KEPI), and multiple eco-efficiency ratios
 Allows the simulation of alternatives and sensitivity analysis aiming the
support of decision making process for continuous improvement
 It is structured in TWO complexity levels (ecoPROSYS Level 1 and Level 2) to
better adjust the eco-efficiency assessment regarding the MATURITY LEVEL
of the company
 Generates profiles of eco-efficiency assessment: Environmental Profile,
Value Profile, Eco-Efficiency Profile) for inner and external comunication

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Conclusions and remarks
 ecoPROSYS© methodology was imbibed into Software Tools by
MicroProcessador and SISTRADE ICT companies in the two levels of
complexity (ecoPROSYS Level 1 – “Base analysis” and Level 2 – “Advanced
analysis”)
 There are strong foundations within the methodology for Continuous
Improvement attitude and eco-efficiency improvement of companies
processes
 ecoPROSYS© is being used in several ongoing projects as a basis for eco-
efficiency assessment, both at a Portuguese National level, but also at
European International level, namely with project SPIRE - H2020 MAESTRI
Total Resource and Energy Efficiency
Management System for Process Industries

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Thank you for your attention
ecoPROSYS: An eco-efficiency framework applied to a medium density
fiberboard finishing line
António J Baptista (abaptista@inegi.up.pt)