Environment & Energy
The careful use of natural resources is an entrepreneurial duty for Porsche. Whether in development or in production: the goal is to minimize the burden on the environment and the efficient use of energy.
Energy & Emissions
CO₂ neutrality in production
For the future, Porsche is aiming for a CO₂-neutral production of its vehicles. A first step will be the production of the first all-electric vehicle - this is to be manufactured from the end of the decade on CO₂-neutral at the Zuffenhausen site. Therefore, at the beginning of 2017, Porsche AG and the subsidiaries Porsche Leipzig GmbH and Porsche Logistik GmbH will switch to 100 percent natural electricity. This gives all German production sites an ecologically sensible energy supply. This will be supplemented by the future use of biogas at the Zuffenhausen site. As part of a cooperation with a municipal plant, the fermentation of biowaste optimizes the energy mix.
New photovoltaic systems at the Leipzig plant
Three photovoltaic plants are currently in operation on the premises of Porsche Leipzig GmbH. A particularly high performance brings the plant on the new body shop. The 15,240 modules generate 4.2 megawatts of electricity. An additional 0.6 megawatts is being provided by the system on the bodywork in which the Macan is manufactured. The roof areas of the new training center, which opened in April, are also equipped with photovoltaic modules. In full sunshine, the system generates a significant portion of the electricity demand. The energy gained through the photovoltaic systems is therefore an important point on the way to resource-efficient production.
Porsche is aware of the responsibility towards its neighbors and takes both technical and organizational measures to avoid or minimize noise emissions. These forecasts serve - in addition to the regular immission measurements - to secure the legal immission standards according to the "Technical Instructions Noise" (TA Lärm). In addition, the results show possible noise reduction potentials and show the development of the noise situation at the site. The control measurements carried out confirm compliance with the limit values.
The careful handling of the environment and resources is not only regulated by Porsche in numerous principles and guidelines, it is also lived in daily work. A large number of measures implemented in 2017 will help Porsche to achieve its long-term goal of saving one million euros annually through the optimized and careful use of resources in production in the year under review.
At the Zuffenhausen site, the GT3 engines on the hot test bench, which have been shortened by fifteen minutes, save around 38,000 liters of fuel per year - without, of course, sacrificing the quality of the test engines, which is always top priority at Porsche. In addition to the approximately 101 tonnes of CO 2 saved each year , this also has a positive effect beyond direct operation: the lower amount of fuel consumed contributes to the reduced overall logistics volume.
The experts in car body construction achieve considerable energy savings through optimized extraction of the smoke produced during welding. Porsche uses less than 400,000 kilowatt hours of electricity per year less. By way of comparison, 45 Porsche 911 Carrera could save CO 2 emissions by about 30,000 kilometers each year with this resource savings. In addition to the environmental benefit, the optimized plant control system also has added value through improved working conditions for local employees.
A considerable proportion of savings is also contributed by the paint shops. In Zuffenhausen, in 2017 alone, an optimization of the application technology on the vehicle body will save coating material worth almost 67,000 euros. In Leipzig, reducing the proportion of fresh air in the recirculating air areas of the paint shop will reduce energy consumption on average by more than 740,000 kilowatt hours per year. This corresponds to an annual CO 2 emissions of around 427 tons - an order of magnitude in the 84 year Porsche 911 Carrera a distance of 30,000 kilometers of CO 2 could cover neutral.
When it comes to the use of fresh water, Porsche strives for a continuous reduction in fuel consumption. On the test and test track at the Leipzig site, rainwater and well water will be used on the so-called dynamic surface to test vehicle behavior on wet roads. An average of 1,340 cubic meters of fresh water can be saved annually.
Resource efficiency in body construction
When planning and building the body shop in Leipzig, the bar for resource-efficient production has once again been raised. These include numerous new, energy-efficient manufacturing processes and the intelligent control of lighting.
Another example is provided by the more than 400 robots in the body shop. So far, functionality and productivity have played an important role in the robots used in production. In cooperation with the Fraunhofer Institute, Porsche has investigated the robot's motion sequences and travel paths: how fast do they accelerate? When do you brake? How long are you on the brakes? When do you actually go into energy-saving mode? As a result, the robots' processes have been optimized so that they also perform optimally in terms of energy. For example, the robots now only accelerate as fast as necessary. It is thus possible to evaluate each individual robot and the entire process sequence energetically.
The body shop thus raises the bar for efficient internal processes: Previously, the certified energy efficiency was decisive on the device. Today it is important that the device is optimally adapted to the work process. This optimization provides energy savings of around 12 percent.
National project "100 companies for resource efficiency"
In Zuffenhausen, Porsche is participating in the "100 Companies for Resource Efficiency" project of the state of Baden-Württemberg in 2017. In the paint shop, by optimizing the driving style in the pretreatment process of the vehicle bodies, besides 5,500 cubic meters of fresh water each year, around 60,000 kilograms of chemicals (for example surfactants, cleaners, pH regulators) can be saved. The process is used as a preparation for the painting process to remove buildup such as lubricants from the body surface.
As a second project, Porsche submitted the energetic optimization for the use of dryer waste heat in the wet chemical waste air purification plant of the Zuffenhausen paint shop. In the exhaust air purification, the required release agent is heated thanks to the optimization by the waste heat flow of the paint dryer. The resulting savings in electrical energy amount to 750,000 kilowatt hours per year, which corresponds to emissions of 319 tonnes of CO 2 emissions.
This commitment was rewarded at the 6th Resource Efficiency and Circular Economy Congress in the Federal Republic of Germany. In the presence of Prime Minister Winfried Kretschmann, Minister of the Environment Franz Untersteller presented two documents to Albrecht Reimold, Chief Production Officer. In addition, both measures will be included as examples of excellence in the book "100 Companies for Resource Efficiency", which will accompany the national project.
Conscious and economical use of water as a resource is an integral part of Porsche's environmental activities. The consumption of fresh water is kept as low as possible. In production, Porsche makes a contribution to the sustainable use of water as a resource and to the preventive protection of soil and water through the use of new, efficient technologies. Thanks to the consistent further development of recycling systems and multiple use, water consumption has been steadily reduced in recent years. Overall, water consumption rose slightly overall in the 2017 reporting period, but the relative value per vehicle produced dropped significantly. The goal of Porsche is to avoid pollution of waters. Polluted wastewater from production is processed decentrally. For this purpose, wastewater treatment plants approved under water law, such as light-weight separators or the neutralization plant of the paint shop, are in operation. The wastewater treatment plants are regularly adapted to the state of the art, which clearly falls below the limits.
Infrastructure & Mobility
Mobility concept for employees
Porsche stands for modern and environmentally conscious mobility concepts. With a comprehensive package of measures, the company also makes an important contribution to air pollution control. Since 2015, employees in the metropolitan area of Stuttgart have been able to use local public transport free of charge. The company ID replaces the ticket. However, Porsche does not only want to make it easier for its employees to switch to buses and trains in the case of particulate matter alarms. Also in commuting between the main plant Zuffenhausen and the outlying Weilimdorf the factory card is valid as a bus or train ticket. In addition, since September 2016, Porsche has been subsidizing the annual public transport ticket with ten percent of the fare and a subsidy of € 20 a month. Even employees who live outside the VVS area benefit from improved conditions. Until now, DB Job Ticket subscribers have paid for ten months, but are allowed to travel for twelve months. In addition, Porsche employees receive a further discount on the annual price.
Anyone who relies on the car on their way to work can now easily pick up passengers at Porsche. The ride-sharing app "TwoGo" puts together carpools for work and service routes. The app combines requests and creates individual timetables. Carpools relieve both commuter traffic and the infrastructure on the premises.
As a further measure to optimize traffic, a parking guidance system was installed in the year under review at the Stuttgart-Zuffenhausen and Weissach locations. An additionally introduced parking app also makes searching for parking even more efficient. In the app a variety of parking garages and parking spaces including the free parking spaces and additional information is displayed. This way, free parking spaces can be found more easily and the so-called slow-moving and search traffic can be reduced to suitable parking spaces.
In recent years, Porsche has been driving forward various projects to promote environmentally friendly logistics. In 2017, these will be further implemented in order to achieve the goals set out in the new "Green Logistics" strategy. Among other things, a methodology is being developed to holistically determine Porsche CO₂ emissions in transport logistics in accordance with the Greenhouse Gas Protocol. The calculation methodology will be further refined and made plausible over the next few years in order to achieve more detailed evaluations.
In view of the increasing traffic load, especially in conurbations, it is important for Porsche to make a contribution to avoiding emissions. In 2017, three CNG gas trucks will be used for daily transport. As a result, up to 20 percent of the previous CO₂ emissions can be saved - around 119 tons of CO₂ per year. The CNG gas trucks emit 80 percent less soot and 90 percent less carbon monoxide. They are also quieter. It is also planned to use LNG gas trucks in the coming years due to the higher range and the promising technology development. The prerequisite is a nationwide expansion of an LNG filling station network.
Green Logistics also means that in the future Porsche new vehicles will be transported by green power by rail for shipment to the seaports. The conversion to green electricity will be prepared in 2017 and coordinated with the transport service providers. As a result, this will save around 6,194 tonnes of CO₂ per year in the future. This corresponds to about 3 percent of the total emissions of Porsche AG in the transport sector in 2016.
The eJIT project started in Leipzig in June of the year under review. The three-year pilot test involves testing a truck with purely electric drive in logistics traffic on the route between the logistics center and the supply center for assembly. Porsche is the first car manufacturer in Europe to use high-speed, all-electric 40-ton vehicles. Every day more than 600 trucks in Leipzig reach the plant - the eJIT is the first truck to be used with purely electric propulsion for transport between the logistics center and the supply center for assembly.
In a second expansion stage, the vehicle will be highly automated from 2018. The e-truck is charged during scheduled waiting times when loading at the supply center. The battery is charged via a 150 kW fast charger. This allows use in three-shift operation. The range at full electric charge is about 70 kilometers, the maximum speed is 85 kilometers per hour. A second electric truck is currently being tested by Volkswagen Sachsen at the Zwickau plant. In Zuffenhausen, the use of an electric truck to supply production from the factory-related transhipment point is planned for 2018. As a result, emissions can be greatly reduced in the plant environment.
In addition to Porsche Leipzig, the research project eJIT involves IAV GmbH, Schnellecke Logistics, Volkswagen Saxony and the network of automotive suppliers. Since the beginning of 2016, the partners have been working together on truck electrification. The project is part of the program "ICT III - Information and Communication Technology for Electric Mobility III: Integration of Commercial Electric Vehicles in Logistics, Energy and Mobility Infrastructures". The Federal Ministry for Economic Affairs and Energy is thus continuing its research activities in the commercial use of electromobility.
In addition to the optimized design of goods traffic, Porsche is also constantly improving its employee mobility management. With the Porsche Global Travel Policy and the Travel Expenses Regulations, a check is made as to whether business trips can be avoided or replaced by the use of video conferences. In order to avoid single trips between the Porsche sites, there is a company-owned shuttle service that covers the frequently used links.
Platinum award for Porsche Industriequartier
Porsche is setting standards in terms of sustainability when expanding and refurbishing the Zuffenhausen headquarters. Plant 4 with the new engine plant, the central workshops and other office space will be certified in October by the German Sustainable Building Council (DGNB) with platinum. This makes Porsche a pioneer in this field. The award recognizes the economic, ecological, sociocultural, functional and technical process quality in the redevelopment and restructuring of industrial districts. Already at the pre-certification in 2015, the plant 4 was considered gold, the highest award category at this time.
In the new engine plant, in addition to V8 engines, the electric drives of the Mission E will also be manufactured in the future. A new building is also being built for the Zuffenhausen central workshops, which will be based on the site of the former Mercedes transmission plant. Here, it was particularly positive that reports on contaminated sites and pollutants had already been prepared in advance of the demolition work and that the recommendations for the refurbishment had not only been implemented, but also accompanied by experts.
In addition, Porsche uses significantly more plants than were required for ecological compensation. The future energy mix with biogas content, the generous retreat spaces with nearby green areas and park-like facilities for employees, as well as the quality of the entire project management were also honored by the award.
For Porsche, the conservation of biodiversity is an essential contribution to the lasting protection of nature and landscape. The aim here is the nature conservation design of the landscape, taking into account the local, landscape-typical conditions at all locations.
Mixed forest instead of coniferous forest monoculture: In Rutesheim, Weissach and Ludwigsburg, several thousand sessile oaks are planted on 4.6 hectares. The trees replace storm-damaged or mushroom-infested spruce and ash forests. Deciduous forests generate an average of 800,000 liters more groundwater per hectare than pure coniferous monocultures - every year and over generations. Porsche is thus supporting the project of the nationwide association "Trinkwasserwald eV" based in Hamburg. The 4.6 hectares of drinking water produce 3.68 million liters of clean groundwater each year. One person consumes about 1,000 liters of drinking water per year; The replanting thus secures the drinking water for up to 3,680 people throughout life.
As part of Porsche's sustainability strategy, Porsche Leipzig is initiating cooperation with the Saxon start-up company "binee". The company, founded in 2015, has developed a recycling cycle that rewards the disposal of old electrical appliances and specifically controls recycling. Thus, the mining of raw materials - such as iron ore - reduced. In a three-month pilot phase, Porsche Leipzig employees have the opportunity to easily and simply dispose of their mobile phones and small appliances on their way to work. Transparent processes provide insight into the recycling chain. This way, the path of the old device can be followed. As a thank you, participants receive a discount coupon for a purchase from a binee partner. The collaboration between Porsche and the start-up "binee" is an example of a successful symbiosis of economic and innovative power in Leipzig.
At the beginning of May, 25 bee colonies, each with around 60,000 bees, will be settled on the grazing area in off-road terrain at Porsche Leipzig. 1.5 million honeybees find a new home on the natural eco-area. The aim is to make a contribution to the securing of the honeybee population and thus to environmental and nature conservation. Thanks to the diverse flora in the off-road area, optimal conditions for the bees are given - here, in addition to numerous wild plants, especially hawthorn, robinia and lime trees. The total area of 132 hectares also serves as a natural habitat for around 30 exmoor ponies and 75 aurochs. Numerous other species - such as pheasants, black kites, amphibians, hares, deer or bats - are native to the area. The concept is unique in the automotive industry. Right from the start, Porsche Leipzig combines sustainable and resource-efficient automobile production with commitment to nature and the environment. The factory off-road site was once a military area and was renatured in 2000.