1998 Environmental Report

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The Bosch Environ-mental Protection logo

Symbolizing clean water, healthy air and a functioning naturalenvironment, the circu-lar shape of the logoalso signifies the com-pleteness of unbrokencirculation systems inboth nature and indus-trial production cycles,from the developmentof products to theirmanufacture and thefinal treatment at theend of their life cycle.

The logo’s Q-shapedappearance provides avisual association withthe Bosch corporate“quality” symbol, serv-ing as an identifyingmark for the continuingpursuit of environmen-tal protection objectivesthat is inseparable fromthe attainment andmaintenance of productquality.

The Bosch Group environmental policy

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Legality

Laws and regulations on environmental protection arebeing strictly observed.

Environmental technology

We are applying the bestpossible technology to protectthe environment, taking intoaccount economic aspects.

Environmental management

We have an environmentalmanagement system in placewhich we are subjecting tocontinuous development. Thesystem includes an organiza-tion with clearly assigned res-ponsibilities and defined dele-gation of tasks.

Contractors

We involve contractors andsuppliers in our environmentalprotection measures.

Public relations

We cultivate a co-operativerelationship with authoritiesand an open dialogue withemployees and the public.

Environmental control

We regularly review the com-pliance with these principlesto ensure the effectiveness ofour environmental manage-ment system. The results ofthe review are subject to eval-uation. If required, correctivemeasures will be implementedin a timely manner.

Environmental protection asa corporate principle

Regard for environmental pro-tection is one of our basic cor-porate principles. We considerproduct quality, economic effi-ciency and environmental pro-tection to be objectives of equalimportance.

Reduction of environmental impact

Environmental protection con-cerns all processes and modesof behaviour in the corporation.Moreover, this includes theeconomical consumption ofresources as well as the acci-dent prevention and the mini-mization of their effects.

Sense of responsibility of employees

Environmental protection isthe concern of every employee.Creating and promotingamong all employees a senseof responsibility for the environ-ment is part of the managerialresponsibility.

Continuous improvement

By way of a continuous im-provement process, we are attempting to control and mini-mize the potential impact ofour overall company activitieson the environment.

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Preface

We are proud to introduceour first-ever corporate en-vironmental report. Coveringall product areas and corpo-rate divisions, it outlines re-levant activities throughoutGerman locations, basedupon information and datathat is current up to the endof 1998.

At Bosch, environmentalprotection has been a majorsubject for a number of years– for all corporate employeesfrom top managers to theworkers on the shop floor.

At German Bosch locationsalone, more than 250 em-ployees are working in full-time positions related toenvironmental protection.

In this brochure, the readerwill gain detailed knowledgenot only of results but also of the efforts applied to thecontinuous improvement ofan established standard, ascontemplated by the Bosch“Continuous ImprovementProcess” (CIP).

Special emphasis must begiven to the commitment of our employees, whichemanates at every turn frombetween the lines of thisreport. It is proof of the factthat environmental protectionwithin our company is notmerely perceived as “a neces-sary evil”, nor as a catch-word of political correctnessthat one likes to enunciatewithout backing it up withappropriate action. Instead,environmental protection hasbecome a natural part of ourlifestyle to which we havecommitted ourselves. As youwill see, environmental pro-tection goes well beyondkeeping the plastic yogurtcups out of the domesticwaste!

Hubert Zimmerer, Member of the Board of Management of Robert Bosch GmbH, responsible for environmental protection

The Bosch Group 6

Core aspects of environmental protection at Bosch 8Bosch Group environmental protection priority ranking 8Environmental Management System 9Resources 10Environmentally compatible product design 12Life Cycle Analysis 12Managing the recycling activities 13Recycling Bosch products 14Environmentally friendly Bosch product packaging 15Handling hazardous materials 16Guarding against dangers 17Protecting the employees at the workplace 18Training measures 19Environmental protection in daily work 19Shipping and transportation 20

Using technology to protect the environment 22Component cleaning 23Materials and processes for painting technology 24Plastics processing 25Remediation of inherited environmental burdens 26Emissions 27

Environmental protection within the Business Sectors 28Automotive Equipment Business Sector 28BoschService. It’s also a little bit of environmental tuning 33Mobile Communications Division (Blaupunkt) 34Communications Technology Business Sector 35Consumer Goods Business Sector 36Power Tools Division 36Bosch Thermotechnology Division 38Household appliances 40Capital Goods Business Sector 42Automation Technology Division 42Packaging Machinery Division 44

Corporate and environmental protection figures 46Environmental protection figures 48

Contact persons 524

Contents

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A brief intro-duction to theBosch Groupand the mani-fold aspects ofenvironmentalprotection which we pursue withinour corporation

We have focu-sed on thesekey environ-mental issueswithin the pro-duction flow inparticular

Examples ofhow environ-ment-relatedimprovementshave alreadybeen incorpo-rated in ourproducts A dash of

statistics, plusadvice on howto find theright answersto questionsyou may have

In total, our EnvironmentalReport attempts to providethe answers to two key ques-tions:

� What measures doesBosch employ to meet thevarious requirements of environmental protection atmanufacturing locations?

� On the side of the enduser, what are the effectsthat are created throughthe million-fold sales ofappropriately optimizedproducts, and through theapplication of these pro-ducts in the daily lives ofour customers?

In this context, it is worthy ofnote that this report, ratherthan describing an attainedstatic condition, discusses anongoing process comprisedof environmental protectionactivities that are undergoing aconstant process of evolution.

In a sense, the Bosch 1998Environmental Report repre-sents a snapshot of our com-pany that is made available toan external observer. At thesame time however, thesepages also address all of ouremployees. First and fore-most, the report conveys tothem a message of apprecia-tion that recognizes their tire-less and successful effortstoward improving environ-mental protection. Second,the information containedherein provides our personnelwith information about theirown workplace and beyond.And, last but not least, thisreport may also be perceivedas a special incentive for allof us.

To provide the reader with arange of subjects of generalinterest to a broad audience,excessive detail was deliberate-ly omitted from this brochure.It is also hoped that as a re-sult, you will find our reportmore readable. And possiblyeven encourage you to join ina dialog with us.

Introduction

The 1998 EnvironmentalReport is the first of its kind,and we have structured it asa kind of general overview.On the one hand, it providesinformation about the varietyof our environmental protec-tion activities and their majoraspects within our enterprise.On the other hand, it goesbeyond corporate divisions,providing a detailed view ofselected products in the indi-vidual Bosch business areas.Although our attention is fo-cused on domestic factories,the central aspects discus-sed here equally apply to our foreign manufacturinglocations.

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In 1998, the CommunicationsTechnology Business Sectorachieved sales of 5.0 billionDM with about 18,700 em-ployees. Its share in totalsales was 10%.

In this Business Sector,Bosch is concentrating onthe public and private net-works, broadband networksbusiness and on the manu-facture and distribution of terminal devices (cordlessphones conforming to theDECT standard, telephonesystems and mobile phones inGSM technology), as well assecurity and aerospace tech-nologies.

Cutting-edge radio relay tech-nology by Bosch for wide-areaapplications in digital transportnetworks is proving a reliablealternative to transmission viaphysical paths

To take advantage of newbusiness opportunities, thekey focus of work in networktechnology has shifted to theareas of transport technologyand connectivity. Specialmention should be given hereto the Bosch Access Net-work for optical data trans-mission, and the radio basedDigital Multipoint System(DMS) transmission system.

In 1998, Bosch introduced aworld first: A precision powersaw for commercial applications

With its 30,800 employees,the Consumer Goods Busi-ness Sector tallied about 11.3billion DM in sales in 1998,amounting to 22% of totalcorporate sales.

Bosch maintains a strongposition in the global marketsfor power tools and accesso-ries. In thermotechnology,Bosch focuses on gas as theenergy source that is particu-larly environmentally compa-tible for heating and hot-watergeneration. Among the rele-vant business division brandnames are Junkers, e.l.m.leblanc, Radson, Worcester,Vulcano and Geminox.

The parity-managed Boschund Siemens HausgeräteGmbH (BSH) is a manufactu-rer of household appliances.

The Capital Goods BusinessSector totaled sales of 2.1 bil-lion DM in 1998, amountingto 4% of total Bosch sales.The number of employeeswas 6,900.

The Automation TechnologyDivision is a provider of inte-grated system solutions forautomated manufacturing.

The Packaging MachineryDivision supplies packagingmachines plus filling systemsfor liquid media to customersin the food processing, semi-luxury foods and tobaccoindustries, to candy manufac-turers as well as to the phar-maceutical and chemical in-dustry.

Tubular bag packaging machine

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Robert Bosch stands as an example of a manwho thought and acted with the whole picture inmind. As an entrepreneur, he adhered to themaxim of applying great energy to addressingspecific issues, even though they extendedbeyond the immediate sphere of responsibility ofa manufacturing company. In this sense, compa-nies and their employees have been activelyconsidering ecological requirements for a longtime – starting with the design, development andmanufacture of a product, and concluding at theend of the product’s cycle of use.

The Bosch Group is organizedinto four Business Sectors:

� Automotive Equipment� Communications

Technology � Consumer Goods� Capital Goods

Automotive Equipment is thelargest Business Sector ofthe Bosch Group. In 1998,123,000 workers achievedsales of 31.8 billion DM,representing more than 63%of total corporate sales.Bosch is the largest indepen-dent manufacturer of auto-motive equipment worldwide.

The Automotive EquipmentBusiness Sector is subdivi-ded into 10 business divi-sions. Nine of these divisionsmanufacture products for theautomobile industry world-wide, and are again dividedinto four large business fields:Fuel injection technology forgasoline and diesel engines;electrical machines (starters,alternators, small-power elec-tric motors); systems for pas-sive and active safety (ABS,ESP, brakes, lighting techno-logy) and mobile communica-tions products (car radios,display and navigation sys-tems, driver information sys-tems).

The Automotive AftermarketDivision is responsible for sell-ing automotive equipment tothe aftermarket trade, and forsupplying service parts. Animportant prerequisite for thesuccess of this division is amarketing and customer ser-vice organization that includesabout 10,000 legally indepen-dent but contractually boundBosch Service agents withabout 100,000 employees in132 countries.

The Bosch Group Headquaters of the Bosch Groupat Gerlingen near Stuttgart

The name of Robert Bosch isclosely associated with theautomobile. However, Boschis not only a byword for auto-motive equipment, such asABS, brakes, fuel injectiontechnology and driver infor-mation systems but alsostands for a number of otherproduct sectors, such ascommunications technologyas well as power tools, house-hold appliances, thermotech-nology, automation techno-logy and packaging machinery.

Bosch develops gasoline directinjection systems for almost allEuropean car makers – to furtherreduce fuel consumption

The Robert Bosch Foundation

“Products, services, andindeed the entire entrepre-neurial philosophy mustinure to the benefit of thegeneral public.” In thissense, the Robert BoschFoundation GmbH is theembodiment of the socialcommitment of our com-pany founder. Having held92% of the Robert BoschGmbH since 1964, thefoundation uses its share ofdividends exclusively for thedirect benefit of the public.By the end of 1998, it hadprovided approximately 825million DM for domestic andinternational public causes.The most significant areasof support are health care,international understanding,public welfare as well asculture and education.

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Under the stewardship of amember of the Bosch Boardof Management, a corporatedepartment within the BoschGroup is charged with theresponsibility for worldwidecoordination, consultation andmonitoring of environmentalprotection issues. This ensu-res rapid implementation ofnew findings related to envi-ronmental protection in theform of decisive corporateaction.

Reporting directly to their re-spective managements, cor-porate environmental protec-tion officers monitor andverify compliance with statu-tes and regulations as well asinternational guidelines. Theyalso advise individual locati-ons about all issues relatedto corporate environmental protection.

Environmental protection atBosch locations abroad

At Bosch, environmental pro-tection abroad has the samehigh priority as at home. Thismeans that Bosch does notmove production into anothercountry in order to circumventcompliance with the environ-mental protection statutesapplying in Germany. On thecontrary, in foreign locationsas well as at home, the com-pany invests considerably infacilities suited to the preven-tion or control of environ-mental impact.

Bosch Group environmental protection priority ranking

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Environmental Management System

In 1995, subsequent to hav-ing conducted successfulpilot projects in France, Spainand Germany, the BoschBoard of Management appro-ved the introduction of theEnvironmental ManagementSystem (EMS). Its underlyingprinciples and concrete guide-lines have been published ina manual that today serves asa benchmark worldwide.

In Europe, the introduction ofthe EMS is organized in acc-ordance with the EU EcologyAudit directive; other locationsadhere to the ISO 14001standard. The EMS providesfor the systematic control ofall activities affecting the en-vironment. Describing the cor-porate organizational structure,responsibilities and process-es, it assists in the ongoingimprovement of environmentalprotection, encompassingenvironmentally friendly pro-duct design to the same extent as operation-specificenvironmental protection andvendor/supplier involvement.

As a prerequisite for suc-cessful environmental mana-gement, all charge personnelmust be aware of their envi-ronmental protection obliga-tions within clearly definedareas of responsibility. Proc-esses, systems and sequen-ces pertaining to the environ-ment are recorded, documen-ted and evaluated. For plantmanagers, this information be-comes the basis upon whichthey formulate environmentalobjectives and a specific program for their respectivelocations.

Each location appoints anenvironmental managementrepresentative who advisesthe responsible departmentsand coordinates all activitiesin the area of environmentalprotection. Employees at allcorporate levels are informedon a regular basis about theeffects their actions haveupon the environment. In thisway, they are sensitized andmotivated to continue actingin an environment-consciousmanner.

Our goal:

Worldwideintroduction bythe end of theyear 2000

Environmental protection officers are supported by a corporate department which isalso charged with monitoringand coordination of the globalintroduction and implementa-tion of the EMS

Bosch environmental protection organizationalstructure

Board of Management

Business Divisions

Subsidiaries

Regional SubsidiariesAbroad

Affiliated Companies

Plants/Factories

Departments

Corporate DepartmentEnvironmental/FireProtectionAccident Prevention

ReportingAdvising/MonitoringAdvising

Within the Bosch Group, environmental protec-tion represents a corporate principle, rankingequally with product quality and corporate profit-ablility. As early as 1973, the Bosch Board ofManagement defined this in a guideline, adher-ence to which is mandatory for all employees. In fact, Bosch has been striving for a long time tominimize environmental impact by assuming pro-active responsibility.

Environmental protection officers

Corporate Departments

Our goal:

Ongoing reduction of specific energy consumption

In many areas, cost savingscan be achieved through re-source conservation basedon the prudent use of energy.However, Bosch also activelyaddresses the conservationof water, our basic resource.Although this “raw material”appears to be cheap, it is byno means available in unlimi-ted quantities. With one-fourthof total water consumptioncoming from our own wellsand three-fourths from thepublic supply, the sparing useof water and repeated recyc-ling through careful water re-covery and treatment havehelped Bosch to reduce waterconsumption even further.

The reasons for particularly low consumption of electri-city include:

� The use of energy-savingdrives with the requisite con-trol technology for heatingand ventilation systems, i. e.,frequency inverter-basedmotor controls, linked to cen-tralized instrumentation andcontrol.

� The increased efficiency ofcompressed air utilization.Because compressed air isgenerated by means of elec-trically powered compressors,it ranks as the most cost-intensive form of energy.Through optimized operationand meticulous maintenancein conjunction with workertraining on a regular schedule,specific losses were reduced.The leakage test for air linepipe systems is also support-ed by a centralized instrumen-tation and control system.

The objectives we have at-tained so far provide amplemotivation to continue withour efforts.

Within the framework ofadapting our buildings andtechnical facilities to the re-quirements imposed by themanufacture of new products,we are refitting these systemswith regard to cost and ener-gy savings. Working together,both our teams of expertsfrom corporate headquartersand technical specialists onlocation synergize in produc-ing energy efficiency studiesthat are bound to become thebasis for the identificationadditional savings potentials.

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Our main energy sources

� Electricity (for lighting, drives, refrigeration plantsand air compressors)

� Natural gas, long-distanceheat supply, light heatingoil (generation of heatrequired for processes andheating applications)

More than ten years ago, wehave completed the ongoingconversion to natural gas as the more environmentally friendly energy source forheat generation. (Today, heat-ing oil serves only as a stand-by energy source to coverpeak consumption periodsduring the winter season.)

Since 1985, heat consumptionper unit area has been reducedby 30%. The reason for this,besides a decisive improve-ment in thermal building in-sulation methods, is the utiliza-tion of heat recovery options:

� Rotary heat exchangers inroom heating ventilationsystems

� Utilization of waste-heatrecovered from air com-pressors for warm-watergeneration

� Utilization of process heat recovery

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Resources

Proportional share of energy sources

Electricity 59% Natural gas 31%

Heating oil 4%

Long-distanceheat supply 6%

1985 1990 1995

400350300250200150100500

kWh/m2yr

Power consumption in Germany per unit areaPower consumption in Germany per unit area

At Bosch, saving energy begins as early asduring the planning phase for buildings andtechnical facilities. The uncompromising utiliza-tion of modern building technology and processcontrol systems (since the beginning of the eighties) provides for the optimized operation oftechnical plant systems, enabling effective ener-gy management with the purpose of protectingthe environment and reducing operating costs.

The highly efficient use ofnatural gas and light heatingoil for the purpose of heatgeneration produces reducedemissions as an immediateconsequence. In addition tothe conservation of resources,the objective here is to reducethe emission of combustiongases, thus making a contri-bution to climate protection.

Despite the strong tendencytoward automation since themid-seventies and the in-creased specific electricityrequirement (referenced tobuilding area and year), wehave been able to keep over-all consumption constant forover ten years.

Rotary heat exchanger

1996 1997 1998

2 500 0002 000 0001 500 0001 000 000500 0000

m3/yr

Water Consumption in GermanyPublic SupplyCompany-owned wells

Hydro dam andturbine (at left)of the Blaichachplant, whichcovers approx.60% of its electricity requirements

Hydro dam andturbine (at left)of the Blaichachplant, whichcovers approx.60% of its electricity requirements

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1998

In 1996, theBlaichach plant receivedan award foroptimizing heatrecovery

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As early as at the conceptua-lization stage of an environ-mentally compatible product,we consider the followingprinciples:

� Resource conservationthrough sparing use ofmaterials

� Selection of ecologicallyfriendly materials

� Selection of ecologicallyfriendly manufacturing processes

� Product utilization orientedtoward environmental pro-tection (low energy con-sumption, low productweight, maintenancefriendliness)

� Repeatability of utilization

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Bosch is active-ly involved inoptimizing therecycling of oldcar parts in ac-cordance withthe “VoluntaryPledge” of Ger-man industry tothe FederalGovernment.We are alsocontributing toongoing workon new con-cepts for elec-tronic scraprecycling

In recycling centers, discardedpower tools and storage bat-teries collected throughoutGermany are dismantled, andthe components recycled. Thesame is true for the specialplastics from old telephonehousings, which are recoveredvia a take-back system usedby the Communications Tech-nology Business Sector.Carrying cases for new elec-tric tools are created fromthese materials. Since 1994,we also take back domesticappliances. In 1998 alone,1,584 tonnes of metals and242 tonnes of plastics havethus reentered the economiccycle.

As an important side effect,new knowledge acquired inthe course of the referred dis-mantling and reprocessingactivities also flows into thedevelopment of new products.This is a practice from whichall business divisions profit inone way or another.

Preventing or reducing wasteis also a major considerationin the planning for new pro-ducts. In this context, minimi-zing the quantities of materi-als used, plus preventing theuse of hazardous substancesboth in production and in thefinished product, are impor-tant goals. Internal standardsand procedures support thefulfillment of this goal.

Waste coordinators are ac-tive at all locations, advisingdesign engineers and manu-facturing planners.

Wherever waste is generated(which frequently cannot beavoided), reduction takesabsolute precedence overrecycling. The basis for this isprovided by the possibility ofseparate collection and stor-age of the respective materi-als. While this concernsmanufacturing in particular, italso applies in other areas.

As an essential prerequisitefor the successful operationof a collection system forseparate materials all wor-kers must be informed andmotivated. To this end, allindividuals are given theopportunity to acquire thenecessary knowledge, and toshare their own ideas andexperiences. An in-housesuggestion system enablesall employees to make anactive contribution to wasteprevention.

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Environmentally compatibleproduct design

Our goal:

Ongoing reduction ofwaste volumes

In the development phase of a product, the courseis set for the entire life cycle of a product – up torecycling or disposal.

Our goal:

Further increaseof recyclabilityof Bosch products

Automotive startercomponents

Managing the recycling activitiesManaging the recycling activities

Life Cycle Analysis

The Life Cycle Analysis (LCA)quantifies the environmentaleffects of a product or processover its entire life cycle. Forexample, energy balance andemissions into the environment(air, water, soil) are document-ed and evaluated. Our centralresearch and advanced devel-opment departments are cur-rently testing various methodsand tools to conduct LCA’s inpilot studies with various busi-ness divisions. For several pro-ducts (e.g., ABS, headlights,fuel injection systems for die-sel-powered vehicles and anglegrinders) LCA’s have alreadybeen issued.

Our business divisions em-ploy advanced guidelines andchecklists. These enable ourdevelopment engineers toestablish additional criteriaand verification options forthe consideration of environ-mental concerns in productdevelopment, which nonethe-less are required to meetspecific requirements in termsof quality and economics.

We use an ecology balancesheet; we test “Design forEnvironment” software tools,and we utilize experiencesacquired with our own collec-tion and recycling systems.We also maintain an ongoingdialog with our customers withregard to additional optionsfor improvement.

In compliance with statutesgoverning recycling economyand waste disposal, we pur-sue higher rates of efficiencyin materials recycling. For se-veral decades, we have provi-ded our support by remanu-facturing (factory recondition-ing) several components.

Easy identification means easy separationEasy identification means easy separation

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Starter before (left) and afterfactory reconditioning (right)

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When a product is “born”,we already take into accountthe end of its life cycle willnot include disposal in alandfill

Internal Bosch guidelines as-sure a recyclable productdesign. For this reason, wemake sure already during theproduct development phasethat the number of differentmaterials is kept low. Where-ver possible, we avoid theuse of compound materialsthat are difficult to separate.

An important developmentobjective of our anti-lockbrake system (ABS 5.3) wasthe practical reusability ofmajor components. The hy-draulic unit contains valuablealuminum; it is easily removedand readily melted down. Theattached control unit andpump motor can also be dis-mantled within 15 secondsand can be reused separately.

Starters and alternators arealso components comprisinghigh aluminum, iron and cop-per contents. At the end oftheir life cycle, they enter intoprofessional remanufacturingat special Bosch reconditio-ning facilities. All componentsthat are suitable for recondi-tioning are dismantled, thor-oughly cleaned and checkedwith care. Worn parts arereplaced with new originalBosch components.

These replacement compo-nents are then assembled inaccordance with the samestrict standards applied tonew products, leaving theplant with a 100% perfor-mance and function guaranteethat is equal to that of newproducts.

Bosch relieves the burden onthe environment by reusingvaluable raw materials. Com-pared to new components,the use of Bosch recondi-tioned starters and alternatorsproduces annual savings ofapprox. 1,800 tonnes of ironand steel, 450 tonnes of alu-minum and close to 100 tonnes of plastics. The annualconsumption of electricityneeded for manufacturingwould amount to approx.85,000 MWh.

The recycling capacity of mo-dern control units has beensignificantly improved by newhousing designs. The newmicro-hybrid technology forcontrol units also simplifiesrecycling. In addition, theminiaturization associatedwith this technology also pro-vides for a significant reduc-tion in the volume of waste.

Recycling Bosch products Environmentally friendly Bosch product packagingEnvironmentally friendly Bosch product packaging

Let’s pack: As much as weneed, as smartly as possible

Packaging is indispensableas a protective medium, infor-mation carrier, and as a “silentsalesman” on the retail storeshelf.

Basic components of theBosch packaging concept arerecyclable boxes with a highcontent of recycled paper.

The dictum of “multi-usebefore single use, and avoi-dance of packaging” is reflec-ted in both in-house deliver-ies and shipments to Boschcustomers. Two-way palletsor grid boxes are used forshipping between manufactu-ring divisions, sales centers

and Bosch contract whole-salers, including most of ourforeign companies.

Also, the decision to phaseout one-way pallets for ship-ments has drawn a positiveresponse from many custo-mers.

In shipping to the automobileindustry, we are increasingthe use of reusable pack-ages, a measure that reducespackaging waste.

We use packages made fromreusable raw materials thatare environmentally friendlyand compact also for ship-ping products destined forthe end user. Our goal:

To increase theshare of multi-use and repeatuse for packages

Thanks to sophisticated fold-ing and stamping patterns,the avoidance of exaggerateduse of color and foil liningand the elimination of plasticfiller materials, Bosch pack-ages have also contributed torelieving the burden on theenvironment.

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1996 1997 1998

12 00010 0008 0006 0004 0002 0000

Units/yr

Reconditioned power tools

Reconditioned starters and alternators

1996 1997 1998

400 000

300 000

200 000

100 000

0

Starters Alternators

Units/yr

Example of an all-cardboardpackaging solution, developedin order to dispense with bubble wrap

Made from plasticregranulate, thisattractive case is atthe same time asales display pack-age, storage caseand transport container

Made from plasticregranulate, thisattractive case is atthe same time asales display pack-age, storage caseand transport container

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At Bosch, theplant fire depart-ments look backon a proud tradi-tion: Some of ourfire departmentswere foundedmore than 75years ago

Out of principle, installationand maintenance of safetysystems adhere to acceptedrules and technological stand-ards. The dates for requiredinspections and maintenanceare tracked by computer.

For example, to prevent ha-zardous situations, we main-tain our own fire departmentsfor deployment as a first lineof defense at more than 30locations in Germany. Morethan 1,000 full-time and part-time plant firemen provideshort response times aroundthe clock when there is anincident.

In the event that fire crewsrequire assistance of a grea-ter magnitude, they can drawupon the support of committ-ed volunteers associated withspecial technical services(chemical clean-up services,medical and public guard services).

For over ten years, and in ad-dition to the specific exerci-ses and training services foreach location, plant fire de-partments have been central-ly trained by our largest firedepartment at the Stuttgart-Feuerbach location. At thisfacility, about 1,900 employ-ees from the various Boschlocations have received theirbasic training and advancedfirefighting courses since1974.

For many years, damage-based losses in the BoschGroup at home and abroadhave been at a low level.Things should stay that wayin the future, too.

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Each worker isissued personalprotective equip-ment for handlinghazardous sub-stances and materials

Handling hazardous materials

Guarding against dangers – also ameasure of environmental protection

For the unavoidable use ofhazardous materials, we defi-ne safe and ecologically com-patible handling procedureswhich are also subject to do-cumentation. For example,appropriate storage areas aredesignated in the plant, tech-nology and capacity are adap-ted to the internal waste watertreatment system or methodsto reuse the generated wasteare defined. Another impor-tant aspect is the selection ofthe appropriate technical pro-tection equipment to preventthe contamination of the wa-ter supply, groundwater andsoil.

Throughout the various busi-ness areas, all hazardous ma-terials being used are record-ed in a directory in order toanalyze and identify the loca-tion and maximum quantitiesof use, and possible effectson humans and the environ-ment. Appropriate measuresare then derived from theinformation thus collected.

Using corporate directives,we educate our workers withregard to possible hazardsand the correct handling pro-cedures and modes of beha-vior. Information regarding thecorrect means of transport isalso a part of the referreddirectives. Special identifyingsymbols and markings warnall workers of hazardous materials.

Incidentally,Bosch firedepartmentsmaintain goodcontacts withtheir counter-parts in neigh-boring commu-nities. In timesof need, onewill come to theaid of the other

Incidentally,Bosch firedepartmentsmaintain goodcontacts withtheir counter-parts in neigh-boring commu-nities. In timesof need, onewill come to theaid of the other

Gone are the days when the hazardous proper-ties of some substances were not fully appreciat-ed, were overlooked or were deliberately disre-garded.

Bosch employees are characterized by a pro-nounced sense of responsibility when handlinghazardous materials – in both their own interestand that of the company.

Prior to procuring productionmaterials or outsourced parts,Bosch technical departmentsevaluate both their technicalproperties and possible effectsupon the environment and onworker health.

An important element forevaluating work materials andpurchased parts is supplierinformation about parts thatare environmentally relevantor related to safety. We haveissued a standard that prohi-bits potentially critical ingre-dients. This standard identi-fies substances that may notbe present in working mediaor outsourced parts, or thepresence of which must bedisclosed.

If the evaluation indicates ahazardous material, a checkis made to determine whetheror not its use can be preven-ted. If a substitution with amaterial featuring a higherdegree of health and environ-mental compatibility does notappear feasible, the quantity,use and release of hazardousmaterials are reduced to theunavoidable minimum.

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Structural buildingmeasures plusmechanical andelectronic devicesare used to storechemicals in amanner that elimi-nates environ-mental hazards

We apply comprehensivemeasures to prevent and restrict fire damages and protect the environment.

To us, the building protectionensured by extensive sprink-ler and automatic fire alarmsystems is as normal as arecatch basins in plant systemshandling ecologically hazar-dous substances. In addition,intelligent safety technologyissues an early warning andhelps limit the escape of ha-zardous substances.

However, warding off danger also necessitatesplanning, preventive, andorganizational measures

Environmental protection en-gineers and safety expertsconduct risk analyses of ma-nufacturing processes andsystems. Employees are trained on a regular schedulewith regard to protectingagainst hazards and their ownresponses to possible eventsof damage. Alarm channels,meeting points and specialmeasures for the occurrenceof such events are tested bymeans of exercises. All of thisis augmented by the respec-tive company instructions andsafety regulations.

Multiple safety devices attachedduring use and shippingMultiple safety devices attachedduring use and shipping

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Robert Bosch –his attentionbelonged notonly to productquality but alsoto the safety andprotection ofworkers in theassembly hall

“Order and cleanliness as aprerequisite for good quality,”were just as important to thecompany founder RobertBosch as taking precautionsin work safety and accidentprevention. In this regard, thesubject of work safety belongsto a proud tradition.

Order and cleanliness arealso the elements of accidentprevention and environmentalprotection. The puddle of oilon the floor can cause a per-son to fall or can also seepinto the groundwater, caus-ing its contamination.

Throughout the Bosch Groupin Germany, work accidentsincreased by 18% as compa-red prior year from 916 to1,086. Considering the impro-ved productivity and the num-ber of newly hired employees,the accident frequency rateper one million working hourswas kept at a low level com-pared to the relevant industry.

Work accidents can occurnot only at the shop or in theoffice, but may also happenon the way to work or duringcompany sports events.

Dangers threaten similarlywhen handling storage orshipping containers andwhen operating the forklift. In 1998, almost half of allaccidents occurred in thetransportation sector.

“Tripping, sliding or falling”represented another majoraccident type – amounting to roughly one-fifth of all accidents.

We perceive the continuousimprovement of the workenvironment to be the mostimportant consequence ofthe foregoing. Danger analy-ses of work areas and equip-ment as well as special reme-dies or protective measuresare instrumental in decreas-ing the number of work accidents and, ultimately, inreducing the effects on theenvironment. Scientific fin-dings provide valuable inputinto the design of workplaces.

Safety and environmentalengineers as well as mana-gers regularly inform com-pany employees about sour-ces of hazards or dangers atthe workplace. In this way,the employees learn to iden-tify and be aware of problemareas.

These efforts are also reflec-ted in the accident statistics.Since 1992 the number ofaccidents has been cut inhalf!

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Protecting the employees at the workplace

At Bosch central headquarters, the tasks of envi-ronmental and fire protection as well as accidentprevention have been consolidated in a joint areaof responsibility. We adhere to the principle thatenvironmentally conscious actions must not ex-clude people – our workers – in their immediateenvironment. Because no one except the wor-kers is exposed so directly to possible hazardsemanating from working materials, work process-es and emissions. The protection of occupationalhealth of personnel at the workplace is an import-ant element of environmental protection.

Clean and uncluttered work spaces: A big factor in reducing work accidents

Clean and uncluttered work spaces: A big factor in reducing work accidents

We reduce strain on the en-vironment through optimizedtest programs in the productdevelopment process: In the Automotive EquipmentBusiness Sector, computer-controlled simulation proces-ses are increasingly replacingdriving tests so that the num-ber of required test kilometerscan be significantly reduced.

Modern error and failure prediction procedures alsoreduce the number of requiredlab tests.

Lab test benches are inspec-ted for weak points and areoptimized using a systematictest bench FMEA (FailureMode and Effect Analysis).This leads to fewer and shor-ter tests, reducing energyconsumption and emissionsat the same time.

In the office, we separate andcollect and separate waste inan environmentally consciousway. Electronic online dataconnections help us promotemethods that reduce theamount of paper required forthe exchange of information.To an increasing degree, busi-ness trips are being replacedby video conferences.

Environmental protection in daily workTraining measures

In Germany, about 40 envi-ronmental protection specia-lists participate in regularinternal and external trainingcourses in order to keep ab-reast of the latest information.

In the course of introducingthe Environmental Manage-ment System, employeesfrom each location were trai-ned to become internal envi-ronmental auditors.

Various technical departmentsoffer training and coursesthrough the Central Office forAdvanced Education. Dedica-ted exclusively or in part tocovering environmental pro-tection issues, courses in-clude, for example, a seminaron environmentally compatibleor recycling-friendly designengineering or a conferenceon environmentally friendly surface cleaning methods.

At workshops and plants,workers meet on a regularbasis in so-called learningseminars. Here they analyzeinnovations and companyprocedures. Topics also in-clude corporate environmentalprotection measures, such asseparating waste accordingto type or avoiding wastealtogether.

Suggestions forenvironmentalprotection havehigh priority with-in the companysuggestion sys-tem. And evenoutside of thenormal worktime, tours andevents concern-ing environmen-tal protectionare quite popular

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Since early 1996, Bosch has employed a con-cept of well-organized cooperation with RegionalShipping Companies (RSC). Since the end of1997, this plan has been implemented through-out Germany.

The ecological requirementsfor the selection of suitablefreight carriers have also beendefined. Among these is theuse of vehicles featuring thelatest technology to ensureeconomic shipping methodswhile preserving the environ-ment in the process.

This concept divides Germanyinto five regions in whichgoods are picked up from thesuppliers, collected at conso-lidation centers and transport-ed in concentrated clustersto the specific Bosch plants.

The RSC concept fulfills eco-nomic and ecological require-ments in equal measure:

The consolidation of shippingevents reduces the number ofshipments. This saves resour-

ces, relieves the burden onpublic transportation systemsand reduces the costs oflogistics.

The reduction of the numberof separate trips, i.e., thebundling of shipments, amounts to an average of 50%and up to 80% in peak times.

In 1997, for example, 2,900tonnes of freight were collect-ed in one region and shippedin accordance with the newsystem, using 753 trucks.Without the RSC concept,2,232 trucks would havebeen required. The reductionthus amounted to 66%.

Additional effects of theRSC concept:

Shipping routes and trans-portation costs are recordedin detail, providing greaterclarity of the resulting ecolo-gical effects. Awarding themajority of contracts to sup-pliers located close to theBosch manufacturing loca-tions causes a shortening of travel distances and lightens the burden on theenvironment.

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Shipping and transportation

Seventy-eightpercent ofBosch workerscome to work bycar (incidentally,this includes anabove-averageshare of carpools). The average is 66%.

On average,Bosch workersneed 23 minutesto get to work(German averageis 21 minutes)

Mathematical models andexperiences with pilot pro-jects indicate that, apart fromthe possible fuel savings ofapprox. 20%, an improvedflow of traffic can significantlyreduce harmful emissions:

� Hydrocarbons by more than 40%

� Nitrous oxide by 25 to 40%

� Carbon monoxide by 25 to 45 %

� Carbon dioxide by 20%

In Germany alone, the intro-duction of improved trafficflows would facilitate fuel sav-ings of several million tonnesannually.

In addition to the attendantfinancial savings and the eco-nomic benefits resulting fromthe reduction of time spent intraffic (in traffic jams, search-ing for parking space), thereis also a savings potential of20 million tonnes of CO2

emissions annually.

In the spring of 1997 we author-ized the Allensbach Institutefor Opinion Research to inves-tigate how employees cometo work and and what meansof transportation they use.

Public transportation is usedmainly in areas of high popu-lation density. This is true forFrankfurt, but also for Berlinor the area around Stuttgart.

Many Bosch locations arelocated outside the city limitsor in rural areas. On average,a one-way trip with publictransport takes 48 minutes as compared to 21 minutesby automobile. Employeesreturning from working thenight shift need 55 minutesinstead of 20 minutes byautomobile.

Traffic flows freelywithout excessive environmental burden

Passengervehicle78%

Public Transport 9%

P+R 5%Pedestrian 4%Bicycle 3%

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Our goal:

In Germany,complete substi-tution of chloro-hydrocarbons by 2002. Concurrently,pursuit of similarsubstitutionpolicy abroad

In the eighties, the dangers ofusing chlorohydrocarbons ascleaning and degreasingagents were recognized.Bosch process developmentcreated new and alternativecleaning methods. Back thenas today, the objective wasand is to replace chlorohydro-carbons in the remaining applications with aqueous or other types of cleaning systems.

Compared with 1988, theconsumption at German loca-tions of solvents based onchlorohydrocarbons wasreduced by more than 95%.The remaining 120 tonnesper year are used in sealedsystems, the operation ofwhich causes only negligibleemissions.

Due to the anticipated shut-down of older productionequipment, the consumedquantity will continue to dropin the years to come. As production quantities declinefor products being phasedout, a conversion to systemsthat operate free of chloro-hydrocarbons is not alwayspractical from an ecologicalas well as economical stand-point.

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The use of chloro-hydrocarbons forcleaning is nolonger the state ofthe art. Today’ssolution areaqueous cleaningsystems

Environmental protection hashigh priority when new manu-facturing processes are intro-duced. These objectives aresystematically anchored inthe requirement profile of therespective processes.

Goals include the avoidanceof emissions, the most effi-cient utilization of materials,conservation of resources,rejection of the use of environmentally hazardoussubstances, plus energy conservation.

A variety of technical solutionshave already been definedand are used in manufacturing.

Here are several representa-tive examples:

Saving water in electro-plating processes throughthe utilization of closedrinse water circulationsystems with integratedreprocessing unit

Recovering valuable mate-rials through reprocessingand recovery of curing andcarburizing salts from cleaning agent solutions orof chromizing electrolytesfrom electroplating rinsebaths

Saving energy through theuse of new and improvedinsulating materials and theuse of burner systems withhigher efficiency rating infurnace systems

Avoiding the use of materi-als constituting an environ-mental hazard by replacingthe heat treatment in cyanidesalt baths with process gastechnology

Several examples of the pastyears will be described inmore detail in the followingpages.

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Using technology to protect the environment

Component cleaningComponent cleaning

Production processes are subject to continuouschange. Methods and practices which in the se-venties mainly followed the dictate of economicsare in the eighties also increasingly viewed fromthe standpoint of environmental compatibility.

Use of chlorohydrocarbonsat Bosch Germany

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Cleaning inprocess lineCleaning inprocess line

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Water-based paints, for exam-ple, are used for coating wind-shield wipers.

Because the paint on wind-shield wipers must be highlycorrosion-resistant, withstand-ing the effects of weatherwhile still retaining an attrac-tive appearance, this type ofapplication is especially com-plex. As a result of intensiveresearch, paint and tech-niques were developed which,for the most part, facilitatethe conversion to water-basedpaint. As a result, solventemissions were reduced by85%.

Another advantage of water-based paint is the fact thatthe overspray (sprayed mate-rial that fails to contact thesurface being painted) canbe easily recovered and re-processed for reuse.

The overspray, amounting toas much as 50%, is recov-ered through ultra-filtration inthe separator system, supple-mented with additives andfinally, by blending with newpaint, restored to the desiredquality.

Paint that hardens by beingexposed to ultraviolet lighthas even less of an effect onthe environment.

Ultraviolet-hardening lacquerdoes not contain any solventswhich would create emis-sions. Overspray can be col-lected and directly returnedto the process without requi-ring reprocessing. To hardenthe paint coat, only one-sixthof the energy needed by aconventional drying oven isrequired.

Bosch is intensively pursuingthe development and intro-duction of these systems.

Painting station for hydraulicvalve housings

Our first applications for thisstation are painting hydraulicvalve housings and pumps forthe common rail injection sys-tem for diesel engines.

Because paint curing occursvery fast, i. e., within 20 se-conds, the equipment can bevery small and compact.

In this example, the UV har-dening module has a lengthof only 2 metres, comparedwith a required length of 40to 50 metres for the dryingoven of a traditional paintsystem.

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Materials and processesfor painting technology

Plastics processingPlastics processing

Some consequences of traditional paint proces-ses using solvent-based paints are atmosphericpollution through solvent vapors, and the genera-tion of waste that must be disposed of at specialhazardous waste sites.

In a joint remedial effort with paint manufacturers,paints were developed that use water as the primary solvent base, containing only minimalproportions of organic solvents.

We apply stringent measuresto materials recycling and theattendant resource conserva-tion. Plastics processing is noexception.

One example is the direct recycling of sprues in the manufacture of plastic parts.

Compliance with material andcomponent specifications atthe points where plastic is in-jected into the mold must beensured. Therefore, transitionzones for the melt materialbetween the mold and themelt injection channels inwhich the plastic bonds withthe component must be pro-vided.

Recovered gra-nulate turns intonew material

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Windshield wiper – metalparts coated withwater-based paint

Sprue waste recycling at theWaiblingen plant

The sprues, i. e., solidifiedplastic from the mold injec-tion gates, are separatedfrom the molded piece, chopped and blended intothe original granulate –instead of ending up in thetrash, as was previously thecase.

Almost every Bosch-manu-factured plastic part is madewith direct sprue recoveryand recycling. Dependentupon the shape of the res-pective part, the savingsamount to between 10 and30%.

Future applications of injec-tion technology will be ableto dispense with sprues enti-rely. In many areas we havealready reached that point.

H2

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X-Cl X-ClX-Cl

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Air emissions

When we burn natural gasand light heating oil, we keepemissions to a minimumthrough the use of moderncombustion systems. Wher-ever pollutants occur as a con-sequence of the manufactur-ing process, we extract themfrom the exhaust or vented airwith the use of separationsystems. For example, elec-trostatic precipitation filtersand oil mist separators effec-tively clean exhaust air that ispolluted with metal cuttingfluids.

We have already converted anumber of processes in orderto prevent the occurrence ofemissions in the first place.Examples: Dry machining ofgeared pumps; baking lac-quer instead of styrene resinto impregnate armatures forelectric motors, and aqueousand powder-based paint coat-ings instead of using solvent-based paint. Wherever dustoccurs, it is filtered from the

waste air, and welding sys-tems are equipped with fumeextraction blowers. Whereverproduct function tests requirethe use of gasoline or oil-bea-ring test fluids, we encapsula-te the equipment to reduceemissions. This also appliesto exhaust fumes from testbenches in development labs.

The Bosch Group currentlyoperates approximately 60plants requiring official certifi-cation, some 50% of whichare heating plants. Other sys-tems comprise engine testbenches, liquefied gas storageand electroplating systems.

Noise emissions

For many years, noise emis-sions at our plants have beenrecorded and evaluated on aregular basis. As a result ofthis work, noise abatementmeasures have been intro-duced, limiting the noise emis-sions to a level that is permis-sible with technical systems.

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Starting in 1984, the BoschGroup in Germany conducteda “survey of inherited environ-mental burdens” at all manu-facturing locations.

Wherever necessary, and incoordination with the respon-sible government agencies,remedial measures for the soil,soil atmosphere and ground-water were initiated. The im-plementation of the majority ofthese measures has alreadybeen concluded.

About 80% of groundwaterand soil contamination werecaused by chlorinated hydro-carbons.

“Cleaning up” soil contamina-tion is accomplished with theuse of vacuum systems withdownstream activated char-coal filters. Groundwater iscleaned through the use ofseparating equipment em-ploying the stripping process.

Stripping system at the Stuttgart-Feuerbach plant

Since 1996 a pilot plant hasbeen used for catalytic clean-ing of groundwater conta-minated with chlorinatedhydrocarbons.

To optimize this new techno-logy, the plant is jointly opera-ted as a research system withthe University of Tuebingen. Itis the only one of its kind inEurope. Chlorinated solventsare broken down by “rusty”iron into harmless substances.Providing an alternative to thetraditional stripping system,the further development ofthis technology is currently inprogress.

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Remediation of inherited environmental burdens

EmissionsEmissionsAll Bosch plants are reducingnoise and pollutant emissions

Our goal:

To clean up oldenvironmental burdens at re-maining locations

Already in the planning pha-ses for new buildings, we cal-culate potential noise emis-sions to determine noise levellimits to be anticipated.These are then consideredand reflected in actual con-struction.

Pilot plant for catalytic cleansingof groundwatercontaminated withchlorinated hydro-carbons

In the next portion of theBosch EnvironmentalReport, we have preparedfor you a “Guide” throughour company divisions.

On the occasion of these“flying visits” you will disco-ver some (but by no meansall) examples of environ-mentally friendly productsand manufacturing methods.These may be deemed re-presentative of our effortstoward effective manage-ment”.*

* Part of the Agenda 21 established by the 1992 EarthSummit held in Rio de Janeiro:Consideration of the needs ofsubsequent generations

At Bosch, the subject of cleaning up inheritedenvironmental burdens is of major importancebecause the protection of soil and groundwateris of great concern to the generations that willsucceed our own.

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Bosch products for automo-tive technologies: their effecton environmental protectionis multiplied several million-fold. This is also a conse-quence of the Bosch so-called“3-S-Program” from theseventies which took its namefrom the German words for“safe, clean, efficient”.

To an increasing degree,manufacturers are replacingmechanical parts with elec-tronic components. Bosch isthe industry leader in thedevelopment and applicationof new electronics-basedsolutions.

In this context, we are focu-sing on three major develop-ment objectives:

� Fuel savings

In addition to conserving va-luable fossil fuel resources,this objective also causes areduction of emissions.

� Weight reduction

As a result of lighter compo-nents, vehicles consume lessfuel and create fewer emis-sions. Less weight also meansthat fewer raw materials areused and therefore less pri-mary energy is required inraw materials production.

� Noise abatement

Automobile driving noise constitutes an additionalstrain on the environment. By optimizing the combustionprocess, e.g., in the case ofdiesel fuel injection, we aremaking another contributionto noise abatement.

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Automotive EquipmentBusiness Sector

In its global operations, Bosch earns 60% oftotal sales through with its automotive equip-ment. We respond in equal measure to the re-quests from automobile manufacturers and theheightened public awareness with regard to en-vironmental issues. Working together with carmakers, we have come closer to the soot-freediesel engine as well as the three-litre automobile.

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The next step toward redu-cing pollutants from gasoli-ne engines

Since the beginning of the fif-ties, Bosch has made a de-termined effort in developinggasoline injection systems.Today, modern vehicles areequipped with fuel injectionsystems that are electronical-ly controlled. While sensorsare monitoring the vehicle’soperating statuses, the enginereceives precisely measuredfuel quantities matching therespective momentary status.In conjunction with the pro-cessing of exhaust gases inthe catalytic converter, theseadvancements have resultedin the production of gasolineengines that emit 16 times

less exhaust emissions thancomparable vehicles at thebeginning of the seventies.

In the near future, our currentproduct developments, suchas direct gasoline injection,will provide for a further 15%of reductions in consumptionfor spark ignition gasolineengines.

New Lambda sensors arefacilitating innovative controlstrategies through improvedsignal quality. This may alsobe viewed as a contributionto reduced consumption andemissions.

In conjunction with sophisti-cated control algorithms, thenew electronic throttle control(EGAS) ensures that theengine is always operated atthe optimal setup for any dri-ving condition. When cold-starting an engine, duringwarm-up or in the event ofengine load changes, the

electronic accelerator helpsprevent unnecessary noiseand emissions.

Another contribution to theseefforts comes from the newintegrated electronic relay(IER) in our starter motors.Facilitating control of the com-plete starting process via theengine electronics, it providesfor additional air intake duringengine warm-up with the aidof the Bosch secondary airpump. As a result, the cataly-tic converter heats up morerapidly during engine starts.

Component weight of thenew EV6 injector was re-duced by 50% as comparedto earlier versions. Among thecontributing factors was areduction of the number of itscomponents. Also, the im-proved tightness of the injec-tion valve improves emissioncharacteristics.

Motronic/EGASME

Throttle valveposition

Oxygen sensor Enginetorque

Ignitionadvance

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TransmissionTransmission

Adaptive Cruise ControlAdaptive Cruise Control

Electronic Stability ProgramElectronic Stability Program

Anti-lock brake systemTraction control

Anti-lock brake systemTraction control

Idle speed-controlIdle speed-control

Flat-tipped broadband Lambda sensor

Electronic throttlecontrol (EGAS)Electronic throttlecontrol (EGAS)

The continuingadvancements inthe developmentof our automoti-ve products willenable us also inthe future tocomply with theautomotive emis-sion and con-sumption regula-tions which arebecoming morestringent world-wide

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Up to now the most efficientexhaust cleaning system forspark ignition engines is a com-bination of catalytic converterand oxygen sensor (Lambdasensor)

Modern diesel injectionsystems from Bosch

Bosch has made importantcontributions to diesel vehi-cles and their environmentallyfriendly operation. A modernexhaust-driven turbochargeddiesel vehicle delivers sub-stantial torque and power,showing almost no visible ex-haust fumes across the entireload range.

Because the fuel consumpti-on with direct-injected dieselengines is approximately35% below that of compa-rable conventional gasolinespark ignition engines, emis-sions of the CO2 greenhousegas are distinctly below thoseof gasoline engines.

Bosch has developed a num-ber of new, electronically con-trolled injection systems formodern diesel engines. Theseinclude the Unit Injector Sys-tem (UIS) and the CommonRail System (CRS).

To reduce fuel consumptionand particulate emissions, thereferred diesel injection sys-tems produce very high injec-tion pressures (up to 2,000bar for the UIS).

Innovative technology for directinjection diesel engines: injec-tors of the new high-pressureinjection system, the Unit InjectorSystem (UIS, left) and the Common Rail System (CRS,right)

Duraterm glow-plug for low-emission dieselstarts

Laser-optics techniques areused to examine the atomizingperformance and mixture pro-cessing properties of a fuelinjection system

The electronically controlledBosch injection systems will facilitate compliance withfuture emission thresholdvalues (e.g., the Euro IIIDirective).

We will of course continue todevelop our injection systemsto further reduce fuel con-sumption, harmful emissionsand noise from diesel engines.

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In recent years,Bosch productsand systemshave been metho-dically optimized,producing weightreductions of upto 50%

Combining aids in reduc-tion. Take the onboard elec-trical system, for example

By using two different batte-ries that have been optimizedfor their respective uses andproviding intelligent electronicenergy management, we havereduced overall weight. As aresult, we have reduced fuelconsumption and exhaustemissions. By combining indi-vidual components into inte-grated subassemblies andmodules, the number of indi-vidual parts as well as theoverall weight of the enginecan be further reduced. Forexample, we are groupingintake pipes, electronicallycontrolled throttle device, fuelinjectors, air cleaner, sensorsand control unit into a com-plete intake module – creat-ing a lightweight intake as-sembly of compact size.

Modern multiplex systems fur-ther contribute toward reduc-ing vehicle weight. The CANbus system developed byourselves can transmit a num-ber of signals on a singledata line, whereas each sig-nal normally requires a sepa-rate cable. In addition to pro-viding a noticeable reductionof vehicle weight, the conser-vation of copper – a valuableraw material – is also an im-portant factor.

Future control units will bemanufactured with the use ofthe newly developed micro-hybrid technology. Comparedto present-day control units,further miniaturization will produce weight savings of a factor of 2 to 3.

The VP44 radial-piston distribu-tor pump for modern diesel injection engines

The weight of electric startingmotors for combustion engi-nes has been reduced by25–50 % since the mid-eigh-ties. This was made possibleby the introduction of theintermediate transmission star-ter with permanent-magnet ex-citation, and through the sys-tematic optimization of allcomponent parts. The weightof the new family of compactalternators (LIC-B) was alsosignificantly reduced by opti-mizing the components andmanufacturing processes –this was accomplished whileraising the efficiency rating atthe same time.

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New, electronically controlleddiesel injection systems fea-ture pre-injection that willmake future diesel enginesrun extremely quiet, whetherduring cold starts or at nor-mal operating temperatures.And for the new family ofcompact alternators (LIC-B),detailed analyses facilitate afurther decrease of operatingnoise emitted by the devices.Raising not only the comfortlevel of passengers but alsoreducing the driving noises ofmodern vehicles passing by.

The fully encapsulated, water-cooled alternator (LIF) willfeature a noise level that isanother 15 to 20 dB lower,rendering it practically inau-dible during vehicle operation.

Bosch also lends an ear tonoise abatement in andabout the vehicle

Modern cars are becomingmore environmentally friendly,also because their operatingnoise is being reduced. Sup-ported by basic research andadvanced methods in thearea of acoustics, significantprogress has been made inrecent years.

Decidedly reduced operatingnoise is also accomplishedby modern Bosch blower sys-tems for engine cooling. Theload-dependent electronicspeed control for the blowermotor also contributes tonoise reduction. And finally,starting the car is madequieter through the combina-tion of modern engine con-trols and the integrated elec-tronic starter relay (IER).

Diagnosis: Everything staysin the green with the rightBosch system

To an increasing degree, self-diagnostic systems are beingintegrated into automotive on-board systems (OBD) requi-ring specific compliance withenvironmental factors. In theevent of a defect which maycause the vehicle’s operationto impose a higher burdenupon the environment, thedriver will be informed andrequested to visit the nearestautomotive service station.The diagnostics systems inlate-generation engine controlsystems detect, for example,defects in the catalytic con-verter, poor combustion andengine “misses”, leaks in thefuel and fuel tank system, aswell as exhaust system mal-functions.

Two measuringdevices in thecold cell with XY-and UV recorder

Injector for the Common Rail System

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As demonstrated, savingspotentials occur primarily inthe areas of materials selec-tion and product design.

We therefore dispense withproblem materials, such asheavy metals, asbestos, phe-nol, chlorohydrocarbons andother materials that constitutehealth hazards.

Already during the productdesign phase, we ensure theuse of gentle surface treat-ment processes. For exam-ple, the new EV6 injector isno longer painted, and itsproof test is performed withair instead of gasoline.

Specialized equipment sepa-rates collected thermoplas-tics, thermoset plastics andrubber waste for reuse.

By selecting the right materials, we reduce energyconsumption and furtherdistance ourselves fromproblem materials

Energy savings potentials areidentified through a compre-hensive approach to evalua-ting the cost of primary energyrequired to manufacture ourproducts.

For example, in the manufac-ture of a headlight, an 80%contingent of the primaryenergy cost accrues in thecourse of manufacturing theactual materials, with the balance of 20% being usedin the further processing ofthese materials.

To confirm fullcompliance withall required mea-sures, BoschService canissue a “BPSEnvironmentalCertificate”

Bosch Service stations arethe home of automotive spe-cialists.

By fine-tuning engine adjust-ments and reducing pollutantemissions to lowest levels,highly qualified technicianscontribute to the preservationof the environment.

There are strict requirementsfor service agents regardingthe procurement, storage,processing and disposal ofmaterials.

As members of the BoschPartner System (BPS), BoschServices have access to awell-organized consulting andsupport system. This makesit easier for each partner toadapt his procedures to thelegal requirements for efficientenvironmental protection.

The training of the environ-mental specialist ranksamong the important ele-ments of the BPS supportpackage.

Bosch Service. It’s also a little bit ofenvironmental tuning

Bosch-Dienst

Verpflichtungzum Umweltschutz

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Automotive Equipment Business Sector

Mobile CommunicationsDivision (Blaupunkt)

The Mobile CommunicationsDivision (Blaupunkt) is wor-king on measures to help carand truck drivers save fueland keep their composurewhile at the same time avoidhaving to wait in traffic.

Blaupunkt equipment withtelematics capabilities calcu-late the geographic positionof the vehicle with the help ofa network of satellites span-ning the globe. Navigationinstructions guide the driverdirectly to his destination,without having to use a map.

In 1998, further improvementswere made. “Dynamic” navi-gation represents an upgradeof the Blaupunkt TravelPilot:For the first time, route re-commendations are supple-mented by current informati-on about the traffic situation.In combination with the 1,800traffic report points installedto-date and the centralizedcontrol facility, the navigationsystem utilizes the continuousstream of incoming traffic datato integrate the resulting find-ings in progressive routeplanning.

In 1998, more than 45.7 million vehicles wereregistered to drive on approximately 231,000kilometers of German roads. As a result, Ger-many has the highest traffic density in Europe.Traffic backups occur during peak holiday travelseasons and while commuters are driving to andfrom work, providing a sense of foreboding of thetotal traffic “gridlock” that has been repeatedlypredicted by traffic experts. Moreover, the referredtraffic backups present an ecological and econo-mical challenge.

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Wherever traffic backupsand developing bottleneckscan be detected and simplycircumnavigated, millions ofautomobiles will save millionsof litres of fuel annually. Thiswill produce a permanentreduction of CO2 emissionswhile increasing traffic safety.

Another goal is to integratedirect report and responseoptions in the respectiveBlaupunkt equipment, enab-ling the motorist to communi-cate with a central controlfacility. In the event of a break-down or other emergency,assistance could be automa-tically summoned from thevehicle.

We developed the Comand(Cockpit Management and DataSystem) electronic driver informa-tion system. With its integrateddynamic navigation system,Comand adapts its route to thetraffic situation. It also providesnumerous operating functions

On German Autobahnexpressways, solar-powered sensors will be installed at distancesof 3.5 km on average,supplying required datato the traffic warningsystem

Infrared sensor

Inductive loops

As the inventor of the classictraffic radio, Blaupunkt hashelped for decades to relievetraffic problems, lighteningthe burden on man and en-vironment.

With regard to the manufac-ture of the respective pro-ducts, the Mobile Communi-cations Division (Blaupunkt)has developed a guidelineentitled “Ecologically Appro-priate Development of CarRadios” as far back as in1992. Experiences gleanedthrough the practical applica-tion of this guideline also cameto bear on ongoing develop-ment:

� Painted surfaces were re-placed by structured sur-faces.

� Component variety hasbeen minimized

� Prohibited materials listswere issued to suppliers(Bosch standard N2580).

� Checklists for all designers

Communications Technology Business Sector

Modern telecom-munications savecost, driving ex-pense and traveltime

In 1996, in the safety techno-logy and private network sec-tors, we were able to reuse1,500 tonnes of electronicwaste. This was done in co-operation with a waste dis-posal company providingsupport in the recovery anddismantling of old equipment.

Bosch has lent a helpinghand to the developmentof the cellular phone.Because it fits in the palmof your hand, Germanshave named it “Handy”

Bosch has developed tele-phone equipment, whichcompared to predecessorsuses 25 % less energy, ismore compact and makes dowithout tantalum capacitorsand rechargeable batteriescontaining cadmium.

In 1996, within the Signomodel series, there has evenbeen a special series of10,000 telephone terminaldevices. To facilitate the re-covery and recycling pro-cess, all housing parts aremade from a single type ofplastic, use a single screwsize for all attachment points,and even the PC board issnap-mounted inside the de-vice without requiring moun-ting screws.

Although precise forecasts are not yetpossible, the experts agree: Substantialenvironmental benefits will also be inher-ent in the communications and safetysystems from this division. Just as Boschaerospace technology benefits the envi-ronment all over our blue planet.

Waste quantity trendsreferenced to finishedproducts (FP)

1996 1997 1998

0.3

0.2

0.1

0

kg/FP

35

37

Wiring and connectors areseparated and cut. The arma-ture and field are broken downat low temperature in order torecover the copper. Iron, steeland castings (transmissionparts, metal paneling, moun-ting devices) that are puremetal are recycled in the hightemperature furnace. PCboards freed of harmful sub-stances go to the foundry torecover metals. Casing, guidesor attached parts made ofaluminum are melted downagain.

Very often, electric compo-nents, such as capacitors,switches or circuit boards,plastic parts inside the powertool, fan wheels, air guideplates or any type of smallpart, must be sorted. Subse-quent to sorting, they can stillbe used, either through heatapplication or as straight ma-terial. Identification of materi-als and the limitation of theirvariety should alleviate thisproblem in the future.

Equipment that cannot bedismantled is submitted toexternal recycling operations.It is then broken down and allferrous metals magneticallyseparated.

Identified plastic parts aresubjected to a granulationprocess, producing regranu-late which in turn becomestechnical parts, accessoriesand transport cases.

36

Even in the manufacture of technical products,environmental concerns can assume a high prio-rity. Our Power Tools Division proves that theexemplary commitment of our workers provides uswith an abundance of suggestions. When theseideas are put into action (58.5% to-date), pride,acceptance and motivation are created: Environ-mental protection becomes a subject of constantdiscussion that is accepted unanimously.

The following belong to theideas already implemented:

� Production free of chloro-hydrocarbons (1991)

� Single-material packagingmade of almost 100%recycled material (1992)

� Design guidelines for envi-ronmentally friendly powertools (1992)

� Power tool recycling, intro-duced already in 1994

AUF 90 adheres to the philo-sophy of achieving ongoingimprovement by continuouslyupdating the subject matter.

However, many small interme-diate steps form one largestep on the path toward animproved environment.

But the end of the ninetiesdoes not signify the end ofAUF 90. What will changewill not be the numerous ac-tivities but rather the name ofthe program. AUF 21 will en-sure the continuation of thisenvironmental program whilemaking the transition into thenext century.

Consumer Goods Business Sector

Power Tools Division

Up to 200parts in onetool – and allare recyclable

The company suggestionsystem for environmentalprotection issues: Five hun-dred eighty-four ideas havealready been implementedthrough the auspices of the“Environmental Action Campaign for the Nineties”(AUF 90)*.

Already in the early eighties,the increasing awareness of environmental concerns caused the Electric Tool Division to formulate an Envi-ronmental Guideline. The year1986 marked the first timethat employees were informedof their special obligationstoward the environment.

After 1990, all associateswere included in defining theenvironmental activities of thebusiness division.

AUF 90 initiated a number of proposals for improvingthe methods of enviornmentalprotection.

Four division coordinators and40 team leaders organizedthe collection of ideas for theenvironment in the areas ofdevelopment, manufacturing,administration and sales.

AUF 90 was established as along-term instrument for onedecade; this was done to un-derscore the importance ofthe suggestion campaign.AUF 90 is now already in itseighth year and for the pastthree years the emphasis hasbeen on implementing selected proposals.

Bosch takes back powertools that have become wornout after years and decadesof use, at no charge andthrough the dealer network.Containing up to 200 indivi-dual parts, these tools aredismantled at a Bosch recyc-ling center, sorted, examinedfor reuse and discardedwhere indicated.

The objective is to dismantleelectric tools into their indivi-dual parts to the extent possi-ble, and to leave less andless material for the shredder.

First, the type of plastic mak-ing up the housing is identi-fied, either by visual inspec-tion, by its coding (Boschplastics ID codes have beenin use since 1992) or byscanning with special devi-ces. Once this is done, thedismantling and separationinto 13 categories can begin.

Power tool recycling: Old componentsreincarnated as new onesPower tool recycling: Old componentsreincarnated as new ones

Sensitizing pur-chasers of techni-cal products

Since 1991,Bosch has pub-lished and distri-buted to its tradepartners two tech-nical informationtutorials describ-ing the methodsof handling powertools in an envi-ronmentallyfriendly manner.Also included arediscussion onrecycling andsales points foruse by environ-ment-consciousprofessionalpower tool dealers

In June of 1992, Bosch issued acomprehensive design guidelinefor power tools. The objective isthe improvement of dismantlingprocedures and recyclability ofmaterials in production, utilizationand disposal

Self-builtbiotope atthe Leinfel-den plant in1990

Self-builtbiotope atthe Leinfel-den plant in1990

AUF 90 figures during its entire term

Total ideas up to 1998: 996Implemented: 55.8% 584Being worked on: 22.1% 220Put on hold: 6.3% 62Cannot be implemented: 13.1% 130

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In June of 1992, Bosch issued acomprehensive design guidelinefor power tools. The objective isthe improvement of dismantlingprocedures and recyclability ofmaterials in production, utilizationand disposal

* AUF 90 = German abbreviation of“EnvironmentalAction Campaignfor the Nineties”

39

The above dia-gram depictscompliance withemission stan-dards by moderngas appliances

However, changing the NOX

and CO emissions of applian-ces is only one part of theoverall environmental aspectin thermotechnology. Anotherimportant task is to reducethe carbon dioxide emissionsfrom gas appliances.

It is currently not possible toremove these harmful sub-stances from the combustionexhaust gases. For this rea-son, only two methods re-main: Conversion to fuels thatburn with low CO2 emissions,or reduction of the use of primary energy.

The manufacturers of gasappliances must thereforeendeavor to increase equip-ment efficiency. This preciselycharacterizes the relevantBosch activities in recentyears.

For example, we have raisedthe efficiency standard of ourconventional gas appliances(Cerastar) by some 5% toabout 90%, and that of fuelvalue appliances (Cerapur) toabout108%(100% =standard).

When compared with thedata in the above diagram,this explains the significantreduction potential that re-sults from the uncompromi-sing use of modern technolo-gy – and especially of fuelvalue technology.

In 1995, the specific carbondioxide emissions for heatingin private households in theformer West Germany (nowofficially termed “Old FederalLands”) amounted to 0.28 kgper CO2/kWh. In the NewFederal Lands, the figure was0.34 kg per CO2/kWh.

38

Besides natural gas, no other primary energysource generates as little CO2 when burned.

In recent years, the Thermotechnology Divisionhas sold a hundred thousand devices withimproved natural gas conservation technology.

In the nineties, the develop-ment of thermotechnologywas characterized by stricterlimit values for hazardous sub-stances and emissions guide-lines, such as those in theamendment to the first regu-lation of the Federal Statuteon Emission Protection(“Small Heating Systems”, 1. BlmSchV). This defines theprerequisites for the “BlueAngle” environmental certifi-cation mark. Similar regula-tions appeared in regionalmodels, such as the Hamburgpromotional program. At thesame time, on the occasionof purchasing a new heatingsystem or water heater, in-creasing numbers of ownersof private homes or apart-ments are prepared to make acontribution toward environ-mental protection, even if thatcomes at a slightly higherprice.

Introduced in 1998, our Ther-moStar vane-type burner ex-plores new avenues in hea-ting technology: Through thespecial arrangement of vanesof different height on the bur-ner surface in conjunction withwater cooling, the combustiontemperature can be directlycontrolled over the entire per-formance range. This reduces

nitrous oxide emissions with-out increasing carbon monox-ide output.

In addition, the Bosch Hea-tronic provides an electronic“brain” for optimal control,simple service and high com-fort.

Thanks to our “Strong Ther-mals” concept, Junkers equip-ment can operate continuous-ly and with minimum expensefor maintenance – and all thisregardless of changing envi-ronmental conditions, such as fluctuating gas quality andpressure, for example.

For water heating with combi-nation equipment, the BoschHeatronic provides three con-trol levels are available. Usingthe ECO setting, the envi-ronmentally conscious usersaves both gas and water. Totrigger the requirement signalfunction patented by Junkers,the water tap need be open-ed only briefly. A little later,the hot water is ready. In con-trast to conventional techno-logy, the user is not requiredto let a large quantity of coldwater run out of the tap, in-stead enjoying “comfort ondemand” in the truest sense.

Consumer Goods Business Sector

Bosch Thermotechnology Division

CO2 formation with various fuels

Fuel usedin kg/kWh

Brown coal 0.40

Hard coal 0.33

Heating oil (heavy) 0.28

Heating oil (light) 0.26

Natural gas 0.20

Interior of themodern Cerapurgas-fired waterheater

Economy without sacrificingcomfort. Good for pocketbookand environment

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1. BImSchV The Blue Angel per RAL UZ61 Junkers Cerapur model

80

60

50

20

10

Downward movement of limit values for emissionshave defined developments in thermotechnology

80

70

60

50

40

30

20

10

0

mg/kWh

NOx mg/kWh

CO mg/kWh

41

The main pro-portion of theeffect of appli-ances on theenvironmentoccurs duringtheir operationin the home. Inrecent years,we have madegreat progressin saving waterand energy

Clear advantage for theenvironment: The AquaSensor

Using a dishwasher is moreenvironmentally friendly thanwashing dishes by hand. Forour new generation of appli-ances, we once again man-aged to reduce the consump-tion of water, energy, salt anddetergents. After rinsing, theAqua Sensor measures thedegree of water turbidity todetermine whether the wateris still clean enough for ano-ther rinse cycle. If this is thecase, one rinse cycle can beomitted. When the dishwash-er is fully loaded and the dishes are not very dirty, ourdishwasher needs 14 litres ofwater. And to keep energyconsumption as low as possi-ble, the heat generated dur-ing the first cycle is used towarm the water for the nextwash cycle.

For increased dishwashingefficiency, some models pro-vide the separate use of thetop basket for cleaning smallloads of dishes.

While on the subject of wash-ing – our washing machinesneed only 0.95 kWh of elec-tricity and just under 39 litres(slightly over 10 gallons) ofwater for a 5-kg load of nor-mally dirty colored laundry ata temperature of 60 °C. TheAqua Sensor measures theturbidity of the water in orderto extend the rinse time or –in the event that the water isfound to be less cloudy – toautomatically reduce the rinsecycles from three to two.

Very clever: Our stoves

Since 1973, the power consumption of our electricstoves for one hour of conti-nuous oven operation hasbeen lowered by 43%.

Individual cooking zonesdetect the diameter of sauce-pans by means of the Autofo-cus feature, automatically ad-justing the size of the requiredheating surface. A so-calledcooking sensor prevent boil-ing-over by constantly mea-suring the pot temperature,enabling the control electro-nics to regulate the heat set-ting automatically. A featurethat is as practical as it iseconomical. Thanks to innova-tive design, the energy con-sumption of our stovetopshas declined by 10 to 15%since 1996.

Energy label: Look before you buy

As early as 1995 we introdu-ced the energy label develo-ped by the European Union.An appliance is rated in sevencategories ranging from “high-ly energy-efficient” (A) to “ex-tremely poor” (G), providingcustomers with a valuable aid in making purchasing decisions.40

In fact, in recent years, Boschwashing machines have re-duced their water requirementper wash by 100 l (to a current49 l), and dishwashers havecut theirs from 60 l (to a plea-santly frugal 14 l). Moderntechnology can make signifi-cant contributions toward con-serving resources.

The energy consumption ofour electric appliances hassimilarly been cut in the last25 years. Washing machinesneed 46% less electricity,dishwashers 57%, electricstoves 43% and refrigerators78%.

Our household appliancesare decidedly economicalwhen it comes to electricityand water consumption rates.Throughout the entire pro-duction process, we are alsostriving to think and act withmore awareness for environ-ment-related issues.

In 1995, we were the first com-pany in our industry to imple-ment the European Ecologi-cal Audit Order. And by theend of 1998, all of our sevendomestic appliance manufac-turing locations in Germanyhad a certified environmentalmanagement system.

Since 1992, the Bosch andSiemens Household ApplianceGmbH (BSH) has document-ed efforts, successes andfuture projects in their ownenvironmental report.

Another measure should becontemplated from the stand-point of informational open-ness and aggressive pursuitof environmental protection:The annual Input/Outputbalance sheet records all en-vironmentally relevant flows ofmaterial and energy passingthrough our plant gates in thecourse of one year.

Consumer Goods Business Sector

Household appliances

Robert Bosch House-hold Appliances GmbHwill be happy to sendyou their current envi-ronmental report:

Robert Bosch HausgeräteGmbHP. O. 10 0250D-80076 MünchenPhone +49 89 4590-00Fax +49 89 4590-2347

Water and electricity consumption figures forBosch washing machines

150

About 34 million washing machines and about17 million dishwashers operate in approximately36 million German households. If each of theseappliances were to save only one litre of watereach time it is used, the volume of water savedin one year would fill a train of tank cars 3,300 kmlong. The volume of water is equal to that flowingdown the Rhine river at Koblenz in the course ofjust under two hours.

105

49

3,2

2,21,7

1974 1986 1998

Water (l)Electricity (kWh)

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Bosch refrigeratorstoday: 0% CFC/HFC, 78% less power con-sumption comparedwith 1974, plus anaverage service lifeof 14 years

43

So that wind power genera-tors never drop their blades

Because they are emission-free, windmill power genera-tors are becoming a primarysource of generating energy.The blades make the actualcontribution to efficiency.

Electro-hydraulic adjustmentdrives from Bosch quicklyadjust the blades to adapt tocontinuously changing windspeeds. The hydraulic cylin-der, control valve and positionmeasuring system are combi-ned into a compact unit in thedrive module in a way thatsaves resources. Further ad-vantages are high functionalreliability, longevity, and resis-tance to wind and weather.

Products are tested hot,the tester keeps his cool

It was already clear in theplanning phase of the endur-ance benches for hydraulicaggregates that the expectedwaste heat should be usedas much as possible to heatthe building and intake air inthe air ventilation system.

At an outside temperature of–12 °C and an average testfield power of 1,150 kWh,

about 76.5% (880 kWh) aregiven off to the cooling waterof the test field. The remain-ing 23.5% (270 kWh) heatgoes to the outside air via theroom ventilation system. Fromthe waste heat, 490 kWh isused to heat the test fieldand intake air as well as thebuilding heating. The remain-ing 390 kWh is removed viathe plant’s cooling water.

42

Radial piston pump

Acquiring gear hobbingmachines which operate “dry”produced the following ecolo-gical and economical advan-tages:

� No cutting fluids needed� Metal chips are treated as

waste (not special waste)� Fire protection equipment

is no longer needed on themachinery

� Reduced manufacturingcosts, shorter processingtimes, longer tool cycles

� No more airborne oil mistin ambient air

Endless filter replaces filterfleece

Frequently, filter fleece fromcutting fluid reprocessingsystems for aluminum machin-ing requires disposal as special or hazardous waste.In the past, only systems withfiltered discharge were used.After several technical chan-ges, it is now possible to re-trofit to endless filter rolls.This concrete example of asystem that machines hous-ings for geared pumps illus-trates the point that environ-mentally beneficial advantagescan be achieved while costsare reduced at the sametime.

� Filter media were saved� Filter change frequency

was reduced� Expense of disposal and

lost oil were reduced

Capital Goods Business Sector

Automation Technology Division

An example of how environmental protection is also economical: Substituting hazardous materials.

Phasing out metal-platedsurfaces

In the past, in order to provi-de rust protection, we phos-phatized the housing and graycast iron parts on radial pistonpumps that are used in indus-trial hydraulic equipment. Thissurface protection requiredten immersion baths for de-greasing, pickling, rinsing andbonding the parts.

The waste water created fromthese processes had to be fedto a waste water treatmentsystem, and heavy metals thatwere filtered out had to bedisposed of as special waste.

Disposal costs of DM200,000 per annum weresaved by providing a rust-freedelivery of raw parts and avoiding rust in the productionprocess.

UV-paint replaces solvent-based paint

Recently a UV-paint systemwas put into operation for theproduction of industrial hy-draulic valves. The goal ofthis investment was to con-vert to a solvent-free paintwhile simultaneously drop-ping the additional phosphati-zing step for the surface. Incontrast to before – paintingwith a spray gun before awater screen and then dryingin an oven – painting is nowcompletely automatic in achamber and hardening isdone in a closed system underUV-light.

Strain on the environmenthas been reduced by:

� Cutting emissions of 300 kg solvents p.a.

� Disposing of 450 kg paintsp.a. from overspray

� Saving several 10,000 kW/hp.a. for drying

Dry machining

The manufacture of gearwheels is a core technologyin the production of gearedpumps for vehicle hydraulics.Before, this was only possiblewith oil as a cooling lubricant.The metal chips mixed withoil required disposal as special waste. Test heat

distribution diagram

Geared Pumps

Gears for geared pumps

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Main heatingdistributor490 kWh

Test fieldcooling water

Plant coolingwater

Buildingheating

310

kWh

40 k

Wh

140

kWh

490 kWh

390 kWh

Test fieldair supply

Plant heatingmains

Operator galleyventilation

Gears for geared pumps

45

Both systemssave materialand energyresources on ascale that liesbetween30–50% depen-ding on the basisof comparison

H-Milk now in a poly-tubebag: A new level of qualityand storage life

In the household, poly-tubebags for milk have the reputa-tion of being difficult to hand-le and easy to break. On theother hand, they are extreme-ly easy on the environmentbecause one litre of productrequires only about 10 g ofpackaging material.

In cooperation with a partnercompany, a new packagingsystem for H-Milk was deve-loped. The bag consists of acombination of various plas-tics, in contrast to containersfor fresh milk. The filled pro-duct is well-protected by thehigh gas and light permeabili-ty of this plastic combination.Along with an innovative sea-ling process, the packagesare drop and tear resistant.However, the ecological ad-vantages of the poly-tube bagand the simple disposal viathe Dual System (in Germany)remain intact. Shipping emptycontainers, which impacts theenvironment, is also a thing ofthe past.

44

This poly-tube bagwon an award in the19th and 20th GermanPackaging Competiti-on in 1996 and 1997

If the contents of a packagespoil and turn to waste, thisburdens the environment. Ifsavings are made at thewrong spot when selectingand manufacturing the pack-aging and the product is in-sufficiently packaged, the dis-advantage for the consumeris usually even greater.

The machine and packagingmaterial form a system that isadapted so well to the pack-aged goods that it offersmaximum product protectionat the lowest possible pack-aging cost.

Capital Goods Business Sector

Packaging Machinery Division

Strength, secure shipping, hygiene, comfortableuse, product protection – these are the essentialrequirements that must be met by modern pack-aging for the retail customer. On the other hand,more and more consumers have become concer-ned about packaging that is perceived as beingtoo elaborate.

Standup bags for babyfood

To protect baby food so thatit does not lose vitamins andother ingredients, it must beprotected against oxygen,light and water vapor. In or-der to remove the oxygen, thepackages are evacuated se-veral times. However, a deepvacuum cannot be createdfor baby food because theproduct itself would clumpup, impairing the solubility. Inaddition, the package must ofcourse be gas-tight, becauseotherwise the quality of thecontents would suffer.

The solution: On a verticalpoly-tube bag machine, acompact square packagemade of compound packagingmaterial is manufactured with a sealing layer, filledunder protective gas, lightlyevacuated and then sealed.Through the prior step of rins-ing with protective gas, thenormally used deep vacuumis not necessary. Expensiveevacuating machinery can beeliminated, without diminishingthe protection of the contents.

The development goal ofcombining clear ecologicaland economical advantageswas attained. Proud proof ofthis is the award we won inthe 19th German PackagingCompetition in 1996.

The standup bag makes itpossible to have 60% betterutilization of the shippingpalette for two 500 g portionsin a carton enclosure. Thereis 90% less waste and 50%less packaging weight for a100% recyclable carton.

Our tube bag for H-milk iscurrently being introduced tothe market in Germany. A study on behalf of theFederal Environmental Officeconfirms that the poly-tubebag package has very goodmarks when measured byecological standards.

Waste that reaches the dumpor is burned, wastewater andexhaust must also be consid-ered when evaluating a pack-aging system.

The result of the poly-tubebag is especially positivehere because little energy isused for its manufacture onaccount of the low weight,and the bag can be incinera-ted without reservations.

This poly-tube bag also wonan award at the Germanpackaging competition.

Bosch is engaged in aggres-sive development work withthe objective of significantlyreducing package weight.

Optimized protection of goodswhile reducing material expen-ditures at the same time, thePackaging Machinery Divisionis working on both, provingits commitment to the envi-ronment on a daily basis.

The new developedaseptic machineryensures a high levelof hygienic safety.Now, H-Milk willactually enjoy thestorage life that itsname promises

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Corporate and environmental protection figures

The following data is a summary of all environmentallypertinent data of Bosch locations (except HouseholdAppliances) in Germany.

For several subject areas, there was extensive datacollected in the past. For others, this data is beingcollected now within the framework of introducing theEnvironmental Management System.

EmployeesGermany Foreign

1 000 1996 1997 1998

200

150

100

50

0

SalesGermany Foreign

40,000

30,000

20,000

10,000

0

Fortunately the developmentof sales and employees hasan increasing tendency. Forimproved clarity, we also indi-cate the foreign component.

Use of various cleaning media

t/yr 1996 1997 1998

500

400

300

200

100

0

Water-based cleanersKW CKW

Of the 827 tons of surfacecleaners used in 1998, 11%was halogenated solvents,38% hydrocarbons and 51%water-based cleaners.

Cooling lubricants

t/yr 1996 1997 1998

4,000

3,000

2,000

1,000

0

non-water-mixable cooling lubricantwater-mixable cooling lubricant

Unit 1996 1997 1998Total Employees 172,359 179,719 189,537Sales Worldwide Million DM 41,146 46,851 50,333

InputEnergy Consumption GWhElectricity 1,090 1,046 1,104Heat (Natural gas, heating oil, remote heat) 1,035 994 765Water Consumption m3

Purchased from Public supply 2,477,863 2,139,445 2,678,838Own supply 894,403 957,627 918,608Land Use Analysis m2

Property Area 8,242,966 8,407,933 8,470,159Green Area 6,429,037 6,515,417 6,648,459Building Area 1,813,929 1,892,516 1,821,700Other Sealed Areas 4,615,108 4,622,901 4,826,759

Selected Raw/Auxiliary and Working Materials tNon-water-mixable cooling lubricants (KSS) 2,738 3,840 3,718Water-mixable cooling lubricants 975 1 086 1 246Oils and Greases 2,343 2,715 3,487Paints and Coating Materials 597 572 604Acids and Alkalies 5,698 6,191 5,317Surface Cleaning Agents 753 833 827

OutputAtmospheric emissions1 tCO2 172,198 165,474 127,916CO 15,3 14,7 11,2NOx (NO + NO2 as NO2) 128 123 95SO2 50 48 33Waste Water m3

Passing into surface water 701,120 774,056 788,992Passing into sewage system 2,419,798 2,136,120 2,591,674

Domestic waste water 855,798 743,435 940,286Untreated plant sewage 759,066 585,367 790,075Treated plant sewage 804,934 807,318 861,313

Solid Waste tWaste for recycling2 55,206 62,013 68,277

of this: requires special monitoring 8,462 10,366 12,895requires monitoring 46,744 51,647 55,382

Waste for disposal2 6,043 4,562 5,524of this: requires special monitoring 4,839 3,900 3,912

requires monitoring 1,204 662 1,612Demolition waste 4,078 6,030 8,267Industrial Waste 10,011 9,653 10,313

1 Calculated from the use of heating material2 Not including demolition waste and industrial waste

Million DM 1996 1997 1998

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In Germany, Bosch operatesa total of 62 systems inwhich are subject to certifica-tion as per the German 4th BlmSchV ordinance. Abouthalf of these systems areheating and furnace systems.

Energy consumption

GWh/yr 1996 1997 1998

1,000

800

600

400

200

0

Air emissions

Emissions are calculatedfrom the determined heatconsumption.

In determining heat consumpti-on, the segment of remote heatwas not considered becausethese emissions were not gene-rated at Bosch locations

Heat consumption

GWh/yr 1996 1997 1998

1,000

800

600

400

200

0

CO2 Emissions

t/yr 1996 1997 1998

200,000

160,000

120,000

80,000

40,000

0

NOX Emissions

t/yr 1996 1997 1998

120

80

40

0

NOX (NO+NO2 als NO2)

The heat used by Bosch isgenerated from natural gas(75%), remote heat (15%),and heating oil (10%).

t/yr 1996 1997 1998

50

40

30

20

10

0

Water usage

The water usage also followsthe trend in production in-crease.

We obtain one-quarter of ourrequired water from our ownsupply, which lessens thework associated with prepar-ing drinking water.

With the dip in 1997, thetabulations for water usageand effluent dischargesreflect a conversion to newproducts in large plants,while the rise in 1998 reflectsthe increase in production.

The discharge into the sewersystem is classified as house-hold waste water and treatedor untreated plant wastewater.

The discharge into waterbodies includes drainage ofrain water and cold water,and approved disposal atpoints where no sewer sys-tem is available.

Household waste waterdischarged into sewagesystem

m3/yr 1996 1997 1998

800,000

600,000

400,000

200,000

0

Plant waste water dischar-ged into sewage system

m3/yr 1996 1997 1998

800,000

600,000

400,000

200,000

0

treated untreated

m3/yr 1996 1997 1998

m3/yr 1996 1997 1998

Effluent discharges intowater bodies

Effluent discharge

Water usage

m3/yr 1996 1997 1998

4,000,000

3,000,000

2,000,000

1,000,000

0

Purchased from Public supplyOwn supply

SO2 Emissions

Effluent discharge intosewage system

Total CO emissions in 1996amounted to 15.3 tonnes, toabout 14.7 tonnes in 1997and 11.2 tonnes in 1998.

2,500,000

2,000,000

1,500,000

1,000,000

500,000

0

Energy consumption

The consumption of electrici-ty and heat varies only littledespite production wasincreasing. This is a result of our efforts toward moreefficient energy utilization.

800,000

600,000

400,000

200,000

0

Current expenses in 1998

Total: 110.53 million DM

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Environmental protection figures

Waste

In 1998, a total of 92,381tonnes of waste were pro-duced. The increase in this annual amount as comparedwith preceding years is ex-plained by the rise in produc-tion volumes. It is worthy ofnote that more and morewaste is channeled into re-cycling of some kind, whileactual disposal waste volumesare receding. The increase indemolition waste confirmsthat the increase in productionis linked to a number of build-ing modification projects. Bycontrast, the volume of indus-trial waste remains virtuallyunchanged.

Industrial waste

10,000

8,000

6,000

4,000

2,000

0

Environmental protection expenditures

The annual costs for environ-mental protection include investments and currentexpenses.

The following fields of activityare differentiated:

1. Waste Management2. Soil/Water Conservation3. Noise control4. Air protection5. Nature conservation/

Landscape preservation6. Soil cleanup

The costs for environmentalprotection in Germany weredetermined for the BoschGroup for the first time in1996. This figure is based onthe methodology outlined inArticle 15 of the Environmen-tal Statistics Law.

This sum includes capital andoperating costs, personnel,auxiliary and operating mate-rials, energy and outside ser-vices – as well as fees, con-tributions and emissionstaxes. All of these expensesare made up of many indivi-dual amounts and measures.

Here are several examples:

Waste disposal fees, operat-ing collection points for resi-dual material, wastewater treatment facilities and clean-ing exhaust air containing oil.

Current expenditure breakdown,per field of activity

100,000

75,000

50,000

25,000

0

1996 1997 1998TDM

Current expenses

1 Wastemanagement34%

2 Soil/Waterconservation49%

3 Noise control 1%

4 Air protection12%

5 Nature conservation/Landscapepreservation1%

6 Soil cleanup 3%

Demolition waste

t/yr 1996 1997 1998

8,000

6,000

4,000

2,000

0

Waste for disposal

t/yr 1996 1997 1998

6,000

5,000

4,000

3,000

2,000

1,000

0Total waste volume

t/yr 1996 1997 1998

80,000

60,000

40,000

20,000

0

Waste to be recycled

t/yr 1996 1997 1998

70,000

60,000

50,000

40,000

30,000

20,000

10,000

0

requires monitoringrequires special monitoring

requires monitoringrequires special monitoring

Cor

pora

te a

nd e

nviro

nmen

tal p

rote

ctio

n fig

ures

20,000

15,000

10,000

5,000

0

1996 1997 1998TDM

Investments in environ-mental protection

Investment

Overall, the Bosch locationsinvested 23 million DM in eco-nomic goods in 1998, whichserve to protect the environ-ment. Soil and groundwaterprotection made up the greatest segment, drainageswere redeveloped as well aschemical stores. Moreover,the wastewater treatmentfacilities were expanded.

Ongoing Expense for Environmental Protection

In 1998, the ongoing expensefor environmental protectionwas about 110 million DM forall locations in Germany.

5

4

6

3

2

1

t/yr 1996 1997 1998

52

Questions about Environ-mental Protection at Boschare answered by:

Central DepartmentEnvironmental/Fire Protec-tion, Accident Prevention(Z4U)P. O. 10 60 50D-70049 Stuttgart

Hartmut MüllerPhone +49 711 811-66 61Michael P. EngelenPhone +49 711 811-68 94

Automotive Equipment Business Sector

Aftermarket ProductsChristian KarnerPhone +49 7 21 9 42-26 24

Original EquipmentRainer KallenbachPhone +49 711 811-73 94

Mobile Communications Division (Blaupunkt)Joachim SchmidtPhone +49 5121 49-46 23

Communications Techno-logy Business Sector

Elmo BehmPhone +49 69 75 05-4113

Consumer Goods Business Sector

Power Tools DivisionPeter HubertPhone +49 711 7 58-28 01

Thermotechnology Division (Junkers)Joachim DettlingPhone +49 71 53 3 06-5 62

Household Appliances Herbert MrotzekPhone +49 89 45 90-21 95

Capital Goods Business Sector

Automation TechnologyDivisionFrank MiederhoffPhone +49 711 811-84 52

Packaging MachineryDivisionBernd WilkePhone +49 71 51 14-28 13

Other Questions about theBosch Group:

The central headquarters of the Bosch Group can bereached under the address:

Robert Bosch GmbHP. O. 10 60 50D-70049 StuttgartPhone +49 711 811-0Fax +49 711 811-66 30http://www.bosch.de

Information about the ProductProgram of the Bosch Groupand Purchase Information canbe obtained from: Corporate Sales and Marketing Department.

You can request product brochures from the Corporate Advertising Department

And scientific literature from the Bosch Group from Technical-Scientific Infor-mation.

The Corporate Public Relations Department will respond to questionsfrom journalists.

Contact persons

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tact

per

sons

53

Pleasecontact us

Robert Bosch GmbHZ4UPostfach 10 60 50D-70049 StuttgartPhone +49 711 811-66 61Fax +49 711 811-70 83Michael.Engelen@de.bosch.comwww.bosch.de 1

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