Site Reports

Tokuyama Factory

Location:
1-1, Mikage-cho, Shunan-shi, Yamaguchi 745-8648, Japan

Number of employees:
1,583

Total site area:
1.91 million m²Main

Products:
Cement, inorganic chemical products, organic chemical products, polycrystalline silicon, fumed silica, polyvinyl chloride, and other products

Tokuyama Factory

Still situated at the Company's first business site, the Tokuyama Factory is the Group's main manufacturing facility, and its products account for about 90% of non-consolidated sales.
The factory operates with the motto, "Go to work healthy and return home happy." Aiming to achieve 6.0 million accident-free hours at the factory and 9.0 million accident-free hours at its contractors, the factory is working hard to keep everyone on site happy and safe at work.
In fiscal 2018, the factory's top priorities are: (1) to identify and eliminate risks related to contact with heat and being caught in, on or between equipment; (2) to conduct active dialogue on safety in order to remove the root causes of continued risks on the production floor; (3) to reaffirm the consistency of actual conditions and work standards for contract work and eliminate sources of risk; and (4) to implement safety point-and-call at crosswalks in facilities, conduct hazard prediction training, and use case studies to raise risk awareness.

Hideki Adachi

Hideki Adachi

General Manager, Tokuyama Factory

Performance Data

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  Unit FY2013 FY2014 FY2015 FY2016 FY2017
SOx emissions Metric tons 750 550 680 750 780
NOx emissions Metric tons 9,200 8,850 8,900 9,500 10,100
Soot emissions Metric tons 174 135 138 138 168
Industrial water consumption Million metric tons 42.2 41.7 42.1 44.1 44.5
Effluent discharged Million metric tons 22.1 23.9 24.2 24.2 24
COD level Metric tons 132 110 124 114 119
Total nitrogen discharged Metric tons 70 89 92 145 173
Total phosphorous discharged Metric tons 2.4 2.6 2.2 2.1 2.1
PRTR-designated substance emissions Metric tons 33 25 36 29 28
Waste generated Thousand metric tons 395 354 389 376 366
Waste sent to landfills Metric tons 277 313 383 368 382
Energy consumption Thousand gigajoules 43,700 44,200 45,100 47,100 49,500
CO2 emissions (originating from fossil fuel) Thousand metric tons 4,020 4,040 4,110 4,290 4,500
Complaints Cases 1 0 1 0 0

Emissions and Transfer of Specific PRTR-Designated Substances in Fiscal 2017 Unit: Metric tons
(mg-TEQ equivalency for dioxins)

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Substance name Regulatory number Amount of emissions Amount
transferred
Atmospheric Water Soil Subtotal
Chloroethylene (vinyl chloride) 94 7.6 0.0 0.0 7.6 0.0
1,2-Dichloroethane 157 6.3 0.0 0.0 6.3 1.6
Chloromethane (methyl chloride) 128 3.8 0.0 0.0 3.8 0.0
Cresol 86 0.0 2.2 0.0 2.2 0.0
Toluene 300 2.0 0.0 0.0 2.0 84.5
Dichloromethane (methylene chloride) 186 1.3 0.0 0.0 1.3 0.0
Chlorodifluoromethane 104 1.2 0.0 0.0 1.2 0.0
1-Bromopropane 384 1.1 0.0 0.0 1.1 0.3
Chloroform 127 0.9 0.0 0.0 0.9 0.0
Hydrazine 333 0.0 0.0 0.0 0.0 0.0
1,2-Epoxypropane (propylene oxide) 68 0.6 0.0 0.0 0.6 2.6
Water-soluble compounds of zinc 1 0.0 0.6 0.0 0.6 0.0
1,2-Dichloropropane 178 0.4 0.0 0.0 0.4 210.1
Carbon tetrachloride 149 0.1 0.0 0.0 0.1 0.0
Benzene 400 0.0 0.0 0.0 0.0 0.3
2,2-Azobisisobutyronitrile 16 0.0 0.0 0.0 0.0 0.0
Water-soluble copper salt 272 0.0 0.0 0.0 0.0 0.0
Hydrogen fluoride and its water-soluble form 374 0.0 0.0 0.0 0.0 0.0
Boron compounds 405 0.0 0.0 0.0 0.0 0.3
Dioxins 243 2.1 20.5 0.0 22.5 0.0
Total (excluding dioxins)   25.3 2.7 0.0 28.0 299.9

・Substances are listed in descending order of emissions levels; substances with no emissions are listed in order of the regulatory number

・Water refers to public waters

・Amount transferred indicates the sum of the quantity transferred to sewage systems and the quantity subject to intermediate treatment

・Total figures have been rounded to the first decimal place

Kashima Factory

Location:
26 Sunayama, Kamisu-shi, Ibaraki 314-0255, Japan

Number of employees:
77

Total site area:
101,000 m²

Main products:
Produced by Tokuyama Corporation
Bulk pharmaceuticals for stomach and duodenal ulcer treatment drugs, and diabetes drugs; optical materials (plastic lens monomer, light modulating materials,and hard coating solutions); raw materials for electronic materials; metal cleaners
Produced by Tokuyama Dental Corporation
Dental materials (restorative materials, adhesives, relining materials, impression materials and investment materials)

Kashima Factory

The Kashima Factory strives to recycle waste matter while complying with environmental laws and regulations and reducing environmental impact. As a result of this approach, the factory recorded a 74% effective utilization rate of waste in fiscal 2017, sent 9 metric tons of waste to landfills for final disposal, and achieved its" zero emissions" goal of 99%. Looking ahead, the Kashima Factory is examining the feasibility of material and thermal recycling as it works to increase its effective utilization rate for all types of waste matter.

Yoshiyuki Kitajima

Yoshiyuki Kitajima

General Manager, Kashima Factory

Performance Data

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  Unit FY2013 FY2014 FY2015 FY2016 FY2017
Industrial water consumption Thousand metric tons 51 48 43 36 39
Effluent discharged Thousand metric tons 66 63 54 50 54
COD level Metric tons 3 3 2 2 2
PRTR-designated substance emissions Metric tons 2 2 2 2 2
Waste generated Metric tons 919 1,020 735 775 761
Waste sent to landfills Metric tons 7 11 20 9 9
Energy consumption Thousand gigajoules 36 36 33 37 39
CO2 emissions (originating from fossil fuel) Metric tons 2,476 2,465 2,246 2,670 2,697
Complaints Cases 0 0 0 0 0

Emissions and Transfer of Specific PRTR-Designated Substances in Fiscal 2017Unit: Metric tons

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Substance name Regulatory number Amount of emissions Amount
transferred
Atmospheric Water Soil Subtotal
Chloroform 127 0.7 0.0 0.0 0.7 20.4
Toluene 300 0.6 0.0 0.0 0.6 33.0
Dichloromethane 186 0.5 0.0 0.0 0.5 21.9
Acetonitrile 13 0.2 0.0 0.0 0.2 5.1
N,N-Dimethylformamide 232 0.0 0.0 0.0 0.0 5.8
N,N-Dimethylacetamide 213 0.0 0.0 0.0 0.0 2.0
2-Vinylpyridine 338 0.0 0.0 0.0 0.0 0.3
Methyl methacrylate 420 0.0 0.0 0.0 0.0 0.0
Total   2.0 0.0 0.0 2.0 88.5

・All figures are the numerical sum for Tokuyama Corporation and Tokuyama Dental Corporation

・Substances are listed in descending order of emissions levels; substances with no emissions are listed in order of the regulatory number

・Water refers to public waters

・Amount transferred indicates the sum of the quantity transferred to sewage systems and the quantity subject to intermediate treatment

・Total figures have been rounded to the first decimal place

Sun・Tox Co., Ltd.

Established:
February 14, 1992

Shareholder:
Tokuyama Corporation (80%), Rengo Co., Ltd.(20%)

Head office:
ORIX Ueno1chome Building, 1-1-10 Ueno, Taito-ku, Tokyo, Japan

Business activities:
Manufacture and sale of biaxial-oriented polypropylene films and cast polypropylene films

Kanto Plant

Sun·Tox's Kanto Plant manufactures biaxial-oriented polypropylene films and cast polypropylene films, which are used for food packaging and other applications. In fiscal 2017, the plant received the Cogeneration Grand Prize for upgrading its gas cogeneration facilities and added another line to its biaxial-oriented polypropylene film manufacturing facility. These high efficiency facilities will help the Kanto Plant to further reduce energy consumption and environmental impacts. The plant also takes part in clean-up activities inside and around the industrial complex to promote harmony with the local community. As it continues to implement three management systems, namely Japan's Occupational Safety and Health Management System (OSHMS), ISO 14001, and ISO 9001, the plant is building on its achievements with the aim to be a community-based factory.

島田 一紀

Kazunori Shimada

Plant Manager

茨城県潮来市島須3075-18

Location: 3075-18 Shimasu, Itako City, Ibaraki, Japan

Number of employees: 204

Total site area: 89,800 m²

Performance Data

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  Unit FY2013 FY2014 FY2015 FY2016 FY2017
Waste generated Metric tons 15 20 15 23 38
Waste sent to landfills Metric tons 4 10 5 10 17
Energy consumption Thousand gigajoules 360 351 356 356 533
CO2 emissions Thousand metric tons 20 20 21 21 26
SOx emissions Metric tons 0.2 0.3 0.3 0.1 -
NOx emissions Metric tons 0.7 0.6 0.7 0.4 0.3
Soot emissions Metric tons 0.06 0.05 0.04 0.02 0.07

Tokuyama Plant

Sun·Tox's Tokuyama Plant manufactures biaxial-oriented polypropylene films, which are mainly used for food and beverage packaging, amounting to about 23,000 metric tons annually. As part of its environmental initiatives, the plant is actively working to reduce perunit energy consumption and increase recycling rates. With respect to safety, it acquired OSHMS certification in 2013 for all of its departments including R&D departments. Under the slogan," Strictly following safety procedures, making manufacturing enjoyable, and never compromising quality," the plant aims to keep its facilities operating safely so it can be depended upon by the community, customers and employees.

中山 信彦

Nobuhiko Nakayama

Plant Manager

山口県周南市晴海町7-7

Location: 7-7, Harumi-cho, Shunan City, Yamaguchi, Japan

Number of employees: 142

Total site area: 24,100 m²

Performance Data

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  Unit FY2013 FY2014 FY2015 FY2016 FY2017
Waste generated Metric tons 66 76 74 84 68
Waste sent to landfills Metric tons 2 1 1 1 1
Energy consumption Thousand gigajoules 463 458 471 463 422
CO2 emissions Thousand metric tons 27 27 27 28 25
PRTR-designated substance emissions Metric tons 0.0 0.0 0.0 0.0 0.0
Complaints Cases 0 0 0 0 0

Sun-Arrow Kasei Co., Ltd.

Established:
February 1, 1999

Shareholder:
Tokuyama Corporation (100%)

Head office:
1-2 Harumi-cho, Shunan-shi, Yamaguchi, Japan

Business activities:
Manufacture and sale of polyvinyl chloride compounds

山口県周南市晴海町1-2

Location: 1-2 Harumi-cho, Shunan City, Yamaguchi, Japan

Number of employees: 29

Total site area: 3,280 m²

Tokuyama Plant

Sun Arrow Kasei's Tokuyama Plant manufactures and sells polyvinyl chloride compounds used for pipes, joints, and other items essential for upgrading infrastructure, as well as PVC window, which are highly effective for saving energy. Practicing ISO 14001 environmental management and having all employees take part in safety and accident prevention efforts has helped the plant to maintain an accident- and disaster-free record for all 18 years it has been operating. Since acquiring ISO 9001 certification in fiscal 2017, the plant has further improved customer satisfaction with a focus on the environment, safety and quality control, while strictly enforcing internal controls and carrying out Responsible Care activities.

安澤 保人

Yasuto Yasuzawa

Plant Manager

Performance Data

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  Unit FY2013 FY2014 FY2015 FY2016 FY2017
Power consumption Thousand kilowatt hours 2,562 2,473 2,659 2,490 2,533
Waste plastic produced Metric tons 125 108 141 135 128
Waste plastic effectively used Metric tons 124 105 141 135 128
Waste sent to landfills offsite for disposal Metric tons 7 8 6 0 0
Steam usage Metric tons 240 240 240 240 240
Industrial water consumption Thousand metric tons 65 65 65 65 65

Tokuyama Polypropylene Co., Ltd.

Established:
April 2, 2001

Shareholder:
Tokuyama (50%), Prime Polymer Co., Ltd. (50%)

Head office:
1-1 Harumi-cho, Shunan City, Yamaguchi, Japan

Business activities:
Manufacture and sale of polypropylene resin and flexible polypropylene resin

山口県周南市晴海町1-1

Location: 1-1, Harumi-cho, Shunan City, Yamaguchi, Japan

Number of employees: 62

Total site area: 70,997 m²

Tokuyama Plant

Tokuyama Polypropylene's Tokuyama Plant conducts risk assessments of processes, facilities,and operations, and takes measures to identify near-miss situations and points of concern,in order to enhance the plant's safety culture. The result has been a perfect accident- and disaster-free record since the time it was first established as Tokuyama's polypropylene film business 42 years ago. The plant is scheduled to obtain recertification in 2018 under the High Pressure Gas Safety Act and the Ordinance on Safety of Boilers and Pressure Vessels, and is pursuing Responsible Care activities with the goals of extending its accident- and disasterfree record, reducing its environmental impact, and eliminating customer complaints related to quality.

田口 勇一

Yuichi Taguchi

Plant Manager

Performance Data

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  Unit FY2013 FY2014 FY2015 FY2016 FY2017
Industrial water consumption Thousand metric tons 411 308 370 333 378
Waste generated Metric tons 116 89 35 77 35
Waste sent to landfills Metric tons 15 2.4* 0 1.8* 0
Unit energy consumption index (fiscal 2002=100) 84 76 71 73 69

Year with periodic maintenance

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