EnvironmentalResponsibility

2

Organisation, facts, figuresProduction sites ....................................... 4Our environmental policy ....................... 6Central environmental management ..... 8Environmental data .................................10

From raw material to ceramic product ... 12

Process-integrated environmental protection .................................................14Tableware division: increase in energy efficiency at the Merzig plant ..................16How potential is developed at our plants .................................................18

Product-related environmental protection .................................................20

Applied research: environment and quality of life .....................................24Dry-COnTrOl .........................................25Or-C-EraM ..............................................26SIMSan ....................................................27KOMPlETT ...............................................28

Confirmation of our environmental activitiesEMaS ........................................................30ISO 14001..................................................31

Occupational safety and preventive health ........................................................32

Definitions ................................................34

The scenic loop of the river Saar, the so called “Saarschleife”, is located very close to the headquarters of Villeroy & Boch in Mettlach.

Table of contents

3

Only a company with the right strategy for the future, such as Villeroy & Boch, can look back on a history stretching back more than 260 years. Our capacity for innovation, coupled with a receptiveness to new ideas while maintaining our proud traditions, has been a suc-cessful formula for the company. Today, Villeroy & Boch has production facilities in Europe, Mexico and Thai-land, and employs more than 8,000 people. This brings with it a high degree of responsibility – to both our employees and the environment.

In terms of environmental protection, it is our aim at Vil-leroy & Boch not to treat environmental issues in isola-tion, but to incorporate them directly into our corporate strategy and process design. The very fact that the ce-ramics industry is traditionally resource-intensive means that we are particularly mindful of the importance of researching, developing and applying new, innovative processes and technologies that both benefit the environ-ment and are economically sustainable.

The use of modern production methods and energy-efficient kilns saves money while substantially cutting CO2 emissions. In addition, here at Villeroy & Boch, we incorporate state-of-the-art environmental technologies into our production processes.

Dear Readers,

As well as during manufacturing, when we develop our products, we ensure not only that they fulfil their func-tion in your home, but that by using them you, as the consumer, are actually helping the environment. We have managed, for example, to reduce the flush volume of our toilets to just 3.5 litres.

Many successes in the areas of environmental protection and the safeguarding of natural resources can be attrib-uted to the commitment of our employees. With this com-mitment, we have been able, for example, to increase the high quality recycling of glazes, and I would like to express my deepest gratitude for this. We encourage this strong identification of the workforce with the aims of our Group by affording scope for individual responsibility. As part of our Ideas Management System, employees actively pro-vide suggestions for improvement, and in doing so help Villeroy & Boch remain an innovative trailblazer and set milestones for environmental protection with its products.

At Villeroy & Boch, we understand that it is incumbent upon each and every one of us to take care of our natural world. Our intention with this publication is to provide you with some information about what we do.

Yours,

Frank Göring CEO of Villeroy & Boch AG

Foreword

Frank Göring

AmericalermaramosSaltillo

Asia/PacificSaraburi

EuropeGustavsbergHódmezövásárhelylugoj

Organisation, facts, figures – production sites worldwide

Villeroy & Boch – a premium brand with a global presence

Innovation, customer-orientation and a clear alignment with the re-quirements of the national and international market have always been the strategic cornerstones of Villeroy & Boch as a traditional company. Established in 1748 as a pottery, the company quickly started to prosper. From its head office in Mettlach, acquired back in 1809 and now the corporate headquarters, Villeroy & Boch exported crockery ranges all over Europe. In addition to tiles, the

company produced mainly sanitary ware from 1900. The success story of tableware continued with a fur-ther product focus – the bath – and Villeroy & Boch established itself as a renowned brand in countries way beyond its national borders.

Today, the focus of our internationalisation strategy is not only Europe, but Asia and America too. It is here, specifi-

cally, that there is a high degree of affinity with traditional European brands. Exports to these continents have risen steadily and will contin-ue to do so.

MerzigMettlachMondsee

rodenroeselareValence d’agen

VargadaTorgauTreuchtlingen

4

Organisation, facts, figures – production sites worldwide

Characteristic of our brand is an integrated range of goods designed to meet the needs of the modern consumer around the globe. What this means is that, in the tableware division, the original range has been augmented by glass-es and cutlery, while sanitary ware has been expanded by the addition of appropriate bathroom furni-ture, fittings and wellness products to provide a complete bathroom range. This strategy of diversifying our product range was accompa-

nied by new production sites in Europe, as well as in Mexico

and Thailand.

2009/2010 COnSOliDATED rEVEnuE in € MilliOnDistribution by division

Bathroom and Wellness 446.6

356

in € million

2010

*Sales figures up to 3rd quarter

2011*

2009426.7

Tableware 267.8

195.3

288.6

V&B Group 714.2

551.3

715.3

0 200 400 600 800

5

Organisation, facts, figures – Our environmental policy

Protection of the environment is one of the fundamental corporate goals of Villeroy & Boch AG. These goals are fully reflected in our Corporate Guide-lines and Ethical Principles and are binding for all employees. Below are some extracts relating to environmental protection:

Our environmental policy

We have a commitment to uphold our name.

Not many companies have made regional economic history as well as European and social history. Villeroy & Boch is one of them, and thus bears many responsibilities. We not only feel obligated to our em-ployees, shareholders and custom-ers, but also to the environment and

society. Preserving natural resourc-es, a sensible approach to the use of energy and a long operating life for our products are all close to our heart. Great importance is attached to occupational safety and preven-tive health at the company.

We obey the law as well as social norms and values.

The wide-ranging nature of our business in various countries and regions means that we encounter a whole host of complex legal provi-sions and obligations. Compliance

with applicable laws, abidance by social norms and observation of lo-cal customs and traditions are all es-sential components of our corporate ethics.

We take on responsibility for safety and the environment.

Villeroy & Boch pursues a systematic policy of continuous improvement in safety and environmental protection management. This accords with our obligation to contribute to sustain-able development. Our approach to these matters is the same as it is to any other area of business; namely, we set goals for improvement and we

measure, assess and report on our performance. Apart from complying with applicable laws and obligations, we constantly strive to achieve im-provements in the corresponding key areas of products, production, tech-nology transfer, occupational safety, and health and environmental protec-tion.

6

We encourage and develop our employees.

Employees and managers are a pre-cursor to the company’s potential for development and performance. The extent to which the potential of technology, information, commu-nication and service are recognised and used depends on their qualifica-

tions, motivation and identification with corporate objectives. For this reason, we feel an obligation to sup-port the people working at the com-pany in both their professional and personal development.

We demand fair and proper business behaviour from our material and service suppliers.

We maintain business relations with those material and service providers that conform to our corporate ethi-cal principles. This includes offering

their own employees fair working conditions – we especially do not countenance child labour.

7

Organisation, facts, figures – Central management for environmental protection and occupational safety

Environmental protection and occu-pational safety form part of our Cor-porate Guidelines. In this respect, the highest responsibility lies with all managerial-level employees who have an influence on environment-related processes – from board level to the production supervisor. Management tasks in all divisions also extend to providing information for and rais-ing awareness among employees on all aspects of environmental protec-tion and occupational safety. They are motivated, within their respective

Central management for environmental protection and occupational safety

field, to develop potential that is both economically expedient and condu-cive to environmental protection and occupational safety.

At the heart of the activities and pro-jects is an improvement in the effi-cient use of energy and raw materi-als and the preservation of resources through improvements in the produc-tion process – particularly a reduction in waste water contamination, CO2 emissions and other emissions such as dust and noise in all process steps.

The setting of environmental targets is directly related to the specifications of the individual plants. Villeroy & Boch has environmental specialists at all of its sites. They are the ones who pursue and promote compliance with planning steps and the attainment of targets – in most cases in coordina-tion with the plant managers. They report annually at group level.

The development of water and emission protection, for example, has been controlled both histori-

8

Organisation, facts, figures – Central management for environmental protection and occupational safety

cally and politically in the individual countries. National legislation is also an influencing factor in this respect. In EU member states, legislation is

gradually being standardised, yet political interests such as emissions trading remain a national matter. Central environmental management

OrGAniSATiOn OF EnVirOnMEnTAl PrOTECTiOn AnD OCCuPATiOnAl SAFETy

has close ties with the respective en-vironmental officers and specialists.

All relevant plant data is analysed in quantified form. As an information platform, environmental manage-ment delivers findings and research results to the individual plants. At the same time, environmental man-agement has both supervisory and advisory roles, concerning REACH for example. This European legisla-tion, which is designed to strengthen consumer protection, is implement-ed rigorously at Villeroy & Boch as a user of chemical additives. The sites are given advisory support in the implementation of environment-related rules and regulations such as EMAS, ISO 14001 and EN 16001.

Plant management

Departmental management

Business division management

Operations management

Management Board

Environmental protection and occupational safety management

Environmental and safety managers at the sites

Headquarters of Villeroy & Boch AG in Mettlach (Saarland, Germany).

9

Organisation, facts, figures – Environmental data

GrOuP EnVirOnMEnTAl DATA FOr 2010

Quantity unit

Ceramics Body 136,863 t (Ceramic raw materials) Glaze 13,794 t

Furniture Wood* 1,000 t

Fittings Metals 2,222 t

Wellness Synthetic materials 4,976 t (shower basins, bath tubs)

Water consumption Fresh water 1,141,241 m3 recycling water 210,330 m3

Energy Electricity 115,049 MWh Fossil fuel (gas, oil) 658,119 MWh

Emissions CO2 191,995 t

Waste water Direct/indirect introduction 837,023 m3

Waste Ceramic raw materials and 18,065 t Ceramic fragments

Further waste Commercial waste 9,118 t Special waste 475 t

* Solid wood, chipboard, MDF boards, melamine boards, plywood boards

10

Organisation, facts, figures – Environmental data

Ceramic products

Basic data unit 2010 Specific consumption unit 2010

Body raw materials t 136,863 raw material consumption (body) t/t(v) 1.3

Glaze raw materials t 13,794 raw material consumption (glaze) kg/t(v) 134.2

recycling materials t 36,353 recycling share % 26.6

Saleable goods t(v)* 102,792

Commercial waste t 7,895 Commercial waste kg/t(v) 76.8

Special waste t 273 Special waste kg/t(v) 2.7

Electrical energy MWh 100,335 Electrical energy MWh/t(v) 1.0

Fossil fuel energy MWh 649,446 Fossil fuel energy MWh/t(v) 6.3

Elec. power consumption share % 13.4

Fossil fuel energy share % 86.6

CO2 emissions t 186,105 CO2 emissions t/t(v) 1.8

Fresh water m³ 1,111,042 Water consumption m³/t(v) 12.9

recycling water m³ 210,330 recycling water share % 18.9

Waste water m³ 825.866 Waste water m³/t(v) 8.0

* t(v) = tonnes of saleable goods

Furniture Fittings Wellness products (synthetic materials)

Basic data unit 2010 2010 2010

raw materials t 1,000 2,222 4,976

Commercial waste t 122 351 750

Special waste t 13 185 4

Electrical energy MWh 2,722 7,793 4,199

Fossil fuel energy MWh 2,726 0 5,947

CO2 emissions t 2,907 179 2,804

Fresh water m³ 1,952 15,062 13,185

Waste water m³ 1,800 7,957 1,400

rESOurCE COnSuMPTiOn AnD EnVirOnMEnTAl DATA FOr 2010

11

From raw material to ceramic product

1. Delivery of raw materials

We receive the various raw materials for the slip (feldspar, crystal, kaolins, clay) and the glaze (feldspar, crystal, zircon, chalk) and aggregates in a va-

From raw material to ceramic product

riety of ways: by ship, silo vehicles and lorry shipments in sacks. A raw materials warehouse is used to re-ceive the bulk goods.

2. Slip Preparation

The raw materials are ground or mixed and packed with aggregates. The hard materials (feldspar, crystal and internally ground, fired sanitary items) are ground up with water in drum mills and the clay minerals dissolved in water with stirring de-

vices. A liquid slip is created from the two suspensions, together with kaolin. After comprehensive control procedures have been carried out by our laboratory, the slip is processed in the production plants.

3. Glaze Preparation

The glaze raw materials in the form of silo goods or goods shipped in sacks are ground, together with wa-ter and any coloured pigments, in drum mills and modern pearl mills. They are then mixed with glaze re-cycled from production and, after filtration, further additives and a fi-nal laboratory check, are used in the glazing departments.

4. Mould production

The processed slip can be processed in the traditional manner in plaster moulds, but also in modern pressure casting moulds made from synthetic material. We manufacture these two types of mould from the “facilities” themselves. We use a special mould-ing plaster and, for the pressure cast-ing moulds, specially manufactured artificial resins.

5. Moulding by casting

Various casting processes are used for moulding:

Battery casting processIndividual casting operation moulds are interconnected and filled via a central slip supply. After a defined period of time, the slip hardens by abstraction to form a hard body. As soon as the body strength has been reached, the rest of the slip is allowed to drain off. It is then collected and

Day silos for hard and soft materials

Drum mill

Storage tank Correction of rheological properties

Magnetic filter

aggregatesKaolin

Mixers

Fine screen

Vibrating screens

Dispersing tank for clays

ClaysWaterElectrolysis

Clays Soft materials

To casting house/ pressure casting plant

WaterCrystal

Feldspar

Grinding media

12

From raw material to ceramic product

reused. After about 60 minutes, the green piece, as it is known, can be removed from the mould.

Pressure casting procedureHere, too, water is abstracted from the slip. However, this is done by means of pressure on the slip and a vacuum in the resin mould. After the body has formed and the green piece has been removed from the mould, the capillary ducts of the mould are rinsed through with water toavoid slip residue.

6. Drying the green pieces

The green pieces are dried before fir-ing. During the drying process, the moisture in the piece is reduced to a minimum.

7. Glazing the greenware

The glaze complements the posi-tive characteristics of the ceramic through the hard, tough surface (high mechanical strength, resistant to scratches, chemicals and other stains).

It is easy to clean and almost impos-sible for bacteria to become estab-lished. In addition, the glaze seals the surface, rendering it resistant to acids and alkaline materials.

The glaze is applied by means of a spray gun operated with compressed air, either manually or mechanically with robots. Inaccessible spots are glazed from the inside.

8. Firing

The glazed pieces are placed on a tunnel kiln car with a heatproof sub-structure. The supporting surface of the kiln car is coated with a release agent, which prevents the ceramic parts from sticking. The pieces are fired in a modern, gas fired tunnel kiln. This involves a computer con-trolled and monitored firing process with a defined temperature/time profile. The waste gases are cleaned in a fluorine separator.

Tableware porcelain goes through the same main production processes such as firing.

13

Process-integrated environmental protection

Process-integrated environmental protection constitutes all activities already scheduled in production.

Process-integrated environmental protection

Thanks to modern technologies, post-treatment strategies such as clarification systems and filters are not actually necessary at all.

The mission to optimise production processes often constitutes a search for cost-cutting measures.

AnAlySiS OF ClEAnED WASTE WATEr

Statutory limit Measured Measured values in mg/l values 2009 values 2010

COD 80.0 < 15.0* < 15.0*

aOX 0.1 0.05 < 0.05*

Filtratable materials 50.0 6.9 7.5

lead 0.3 < 0.01* < 0.01*

Cadmium 0.07 < 0.002* < 0.002*

Cobalt 0.1 < 0.01* < 0.01*

Chrome 0.1 < 0.01* < 0.01*

Copper 0.1 < 0.01* < 0.01*

nickel 0.1 < 0.01* < 0.01*

Phosphor 1.5 0.2 0.1

Zinc 2.0 0.2 0.2

Measured values: average per year * below the detection limit

Filtration modules are the centrepiece of a recovery plant for the glaze.

The results of the systematically ex-amined waste water show a consider-able reduction in the level of harmful substances discharged into the Saar. The levels are well below legal limits for all relevant measured parameters. Filtratable materials, for example, amount to no more than a quarter of the permissible limit. COD pollution is under 15 mg/l, where the permissible value is 80 mg/l. The quantity of zinc measured in the waste water is below 10% of the limit value. The aOX value is below 50% of the limit.

WASTE WATEr VOluME DiSCHArGED inTO THE SAAr

450.000

400.000

350.000

300.000

250.000

200.000

150.000

100.000

50.000

02000 2002 2004 2006 2008 2010

Waste water volume in m3

Use of raw materials

14

One of the many projects imple-mented at Villeroy & Boch which vouches for process-integrated en-vironmental protection is the in-tegration of state-of-the-art waste water technology into the glaze treatment process. Such technol-ogy has enabled Villeroy & Boch to reduce the volume of waste wa-ter discharged into the Saar River from 407,000m³ to 230,000m³.

To achieve this, the waste water cleaning system has been devel-oped based on three different cleaning principles. In addition to a small, modern clarification plant, diaphragm technology is used to recover the homogene-ous white glaze.

In this way, for example, the solids that would normally be discharged into the clarification plant are not only trapped, but are also reused directly as a high-quality white glaze for the spray robot.

The third pillar of the system is based on local treatment of the waste water flow directly at its source. This avoids the need for chemicals, and the waste water can be discharged into the mu-nicipal clarification plant. This process innovation can also bring about a saving of around 1,500 MWh of electricity per year at the clarification plant. This is equivalent to around 1,000 tonnes of CO2 per year.

Process control for the direct print machine at the Merzig plant

15

in the period 2005 – 2010, around 48,000 tonnes of CO2

CO2 emission during heat generation in the sanitaryware factory in Mettlach (in tonnes)

14.000

12.000

10.000

8.000

6.000

4.000

2.000

02005 2006 2007 2008 2009 2010

Process-integrated environmental protection – Increase in energy efficiency at the Merzig plant

The impressive potential for increas-ing energy efficiency can be seen in the example of the firing kiln. Op-timisation based on real-life condi-tions can produce a CO2 saving of 4,200 tonnes per year.

Five interlocking measures are piv-otal in the project. Firstly, insula-tion of the body of the kiln has been improved by fibre linings, which on the one hand produces a direct sav-ing on the heat energy used and on the other reduces the heating up and cooling down phase, which in turn simplifies the maintenance work and enables the firing programme to be changed more quickly. Improved in-sulation accounts for around 20% of the overall saving.

A further 30% share of the energy saving can be attributed to the uti-lisation of waste heat from the cool-ing zone for drying and pre-heating the kiln run. The radiant heat gener-ated by the firing process in the ce-ramic pipes is dissipated to pre-heat

other goods. This means that no ex-ternal energy supply is required for pre-heating, and also helps keep the temperature of the kiln as constant as possible. Regular losses are also avoided.

Tableware division: increase in energy efficiency at the Merzig plant

use of bulk ceramic material for the non-load-bearing part of the kiln car

Kiln furniture with ware

16

The most energy-intensive process in the manufacture of ceramic products is the firing process in which tempera-tures exceed 1,200 °C, which gives rise to the typical char-acteristics of ceramic products.

Breakdown of energy sources: over 85% natural gas and just under 15% electrical energy.

Three production sites are subject to emissions trading in accordance with the criteria set out in the German Green-house Gas Emission Trading act (Treibhausgas-Emissions-handelsgesetz, TEHG). The graphics show the develop-ment of CO2 emissions at the two sanitaryware plants in Hungary and romania, and also the CO2 emissions of the central boiler at the sanitaryware factory in Mettlach, which is subject to emissions trading.

SAniTAryWArE: EMiSSiOnS TrADinG AnD CO2 EMiSSiOnS

were saved at the three sites (after deducting the certificates initially bought in).

CO2 emission

CO2 emission (bought in)

CO2 emission savings of allocated quantity

CO2 emission at lugoj (romania) in tonnes

24.000

23.000

22.000

21.000

20.000

19.000

18.0002007 2008 2009 2010

CO2 emission at Hódmezövásárhely (Hungary) in tonnes

30.000

25.000

20.000

15.000

10.000

5.000

02005 2006 2007 2008 2009 2010

Wolfgang Schneider, technical development of tableware and initiator for the implementation of energy efficiency.

The pre-heating of air in the com-bustion process when the heating gas is burned can also help to pro-duce a further 20% saving overall by absorbing energy from the indirect cooling zone.

The energy requirement is also re-duced thanks to an innovative rede-sign of the kiln car and the use of bulk ceramic material to fill energy losing areas. This results in a further 20% reduction.

And finally, optimised moulding and material shaping of the kiln furni-ture allows for an improved ware to furniture ratio, producing a further 10% energy saving.

17

Process-integrated environmental protection – How potential is developed at our plants

The notion of environmental pro-tection has long since made its way into all production processes, and the employees at Villeroy & Boch demonstrate their commitment in the many development and im-plementation measures to reduce the consumption of resources and emissions.

LED lighting reduces electric power consumptionEven our youngest employees are aware of their responsibility to play an active role in helping to protect the environment. The trainees at our electrical apprenticeship work-shop in Mettlach have drawn up the following example of an ac-count based on an analysis of the existing lighting stock in the Mu-

seum, Keravision and Sanitaryware Exhibition departments. By gradu-ally replacing the existing halogen lighting with LED lamps, the power consumption for lighting can be re-duced by 80%, as modern LEDs, in terms of like-for-like light output, consume just 4.5 watts compared with the 20 watts consumed by the halogen lamps used previous-ly. Moreover, in addition to being more durable, LEDs are both im-pact- and vibration-resistant, and the light emitted by them contains no ultraviolet or infrared radiation. Thanks to the low level of heat dis-sipated by LEDs, the output of air-conditioning systems in buildings can be reduced in summer. The 1,000 lamps installed at the Experi-ence Centre in Mettlach are expect-

ed to cut CO2 emissions by around 20 tonnes per year.

The switch to LED lighting is also underway at other sites, for example in Mexico, Hungary and Romania, where substantial savings are being achieved due to lower consumption of electric power. As LED technolo-gy is continuing to develop and con-version to the new type of lighting is feasible in practically every area, this measure will be promoted even further within the Group.

Cooling using groundwaterAt the production facility in Ro-den in the Netherlands, instru-ments and equipment essential for the different production processes are successfully cooled using heat transfer with groundwater. This in-novative technology reduces the plant’s drinking water requirement by around 50,000 m³ annually, and reduces electric power consumption for cooling units – and thus CO2 emissions – to almost zero. Relevant heating of the groundwater at a con-veying depth of 99 metres does not occur because the temperature am-plitude between water conveyed and pumped back is only 4°C.

How potential is developed at our plants

Our trainees eagerly measure the energy consumption and determine the potential saving for the environment.

18

Utilisation of waste heatAt the Villeroy & Boch sanitary-ware plant in Romania, the focus in terms of environmentally friendly technology is on heat recovery. The installation of heat exchangers in the various production lines is cur-rently saving some 646 tonnes of CO2 emissions per year.

At the Villeroy & Boch tableware ceramics plant in Torgau in the German state of Saxony, the flow of waste heat from the firing kiln is used for glazing the items. The heat output by the first air/water heat exchanger installed at the plant is around 100 KW per hour. This dries the goods in the storage area prior to further processing, heats the production and storage rooms, and prepares the hot water in pro-duction and social systems. Based on the extremely positive experi-ences and the enormous amount of energy recovered, similar types of systems are planned for the plant’s other two kilns. This means it will be possible to satisfy the overall de-mand for hot water and basic heat-ing at the Torgau site.

Roeselare plant: material and energy savings There is also investment in green innovation at the Roeselare site in Belgium, where wellness products such as bath tubs and whirlpools are manufactured. Over a two-year period, Villeroy & Boch managed

to develop a new moulding process for acrylic products at the plant. This method of manufacturing re-duces both production waste and materials consumed (in the latter case by 10-15%). It also means that less energy is consumed over-all in the course of the production cycle.

A new horizontal stacking method is also employed in Roeselare to accommodate the extremely large bath products. The aim is to make better use of the space available in a delivery vehicle while at the same time minimising the risks to the safety of delivery personnel using a “manipulator”. Both issues – and in particular the safety aspect – have been confirmed by extensive tests.

37% CO2 reduction at the furniture factory in MondseeIn the case of exhaust systems in particular, energy consumption can be reduced by optimum plant design or subsequent modernisa-tion of existing plants, as illustrat-ed by the furniture factory in the Austrian town of Mondsee. A pat-ented SEPAS system, which came into operation this year, is used to adapt the suction power to the re-spective capacity utilisation of the machine.

The conveying and delivery system is controlled fully automatically ac-cording to the type and quantity of

the materials. The suction effect re-mains consistently good, even when the energy consumption is marked-ly reduced.

An exterior temperature sensor is used to switch the outlet air or re-turn air automatically, and the heat energy recovered is adapted to the daily temperature curve. This re-duces heating costs and CO2 emis-sions.

This environmental benefit of around 83 tonnes of CO2 per year is equivalent to the amount of CO2 emitted by 50 medium-sized cars doing around 6,000 miles a year.

Another project – currently in plan-ning – involves heat recovery for surface treatment, and is intended to do away entirely with the fossil fuels used to date. Implementation is planned for 2012.

Both projects combined will reduce CO2 emissions by more than 400 tonnes per year (over a third).

Much has also been done in the area of lacquering. The move away from solvent-based lacquers to wa-ter-based suspensions has helped bring about a significant improve-ment in health and safety condi-tions and environmental impact.

Silo for storing wood shavings for energy recovery in Mondsee.

19

Product-related environmental protection

2 volume flush

Villeroy & Boch, in cooperation with the company Geberit, is Europe’s first provider of a 2 volume flushing system. The two button actuator offers a flushing volume of either 3 or 6 litres. The product is a clear indicator of Villeroy & Boch’s responsible attitude to the use of natural resources.

AquaReduct 4.5 litre toilet

With AquaReduct, Villeroy & Boch is one of the first providers of a 4.5 litre toilet as a permanent feature of the collection: an innovation that saves water and money – without compro-mising the power of the flush. Villeroy & Boch currently offers a com-prehensive AquaReduct portfolio.

Innovation CeramicPlus

With CeramicPlus, Villeroy & Boch offers a completely new surface refinement system that has proven its worth millions of times to date. Care is made far easier, and the saving on deter-gents and water makes a great contribution to individual environmental protection.

0 litre urinal

Innovative Villeroy & Boch siphon technology for minimal water consumption: the Subway AquaZero 0 litre urinal project, in addition to financial savings, also requires a reduced servicing effort.

2 volume flush

0 litre urinal

1996

2005

1998

20

Product-related environmental protection

Because sustainability is in our natureThe time bar shows the development of sanitaryware at Villeroy & Boch by way of selected examples. We are looking to consume ever fewer resources in production, while at the same time offering our customers products that save both energy and water.

0.8 litre siphon for urinals

Villeroy & Boch has redesigned the siphon for urinals, and in doing so has set new standards for saving water: at just 0.8 litres of water per flush cycle, the new urinals are far more economical, and thus environmentally friendly, than convention-al siphons that consume a flush volume of between 2 and 3 litres.

3/4.5 litre Subway 2.0

The new design of the wall-mounted Subway toi-lets has also optimised the inside of the toilet: the result is Subway 2.0, with a 3/4.5 litre AquaReduct – with an optimised flush-ing performance. The new innovation makes the Villeroy & Boch portfolio of AquaReduct toilets one of the widest-ranging on the market.

2/3.5 litre Omnia Architectura GreenGain

The GreenGain toilet from the Omnia Architectura collection is revolutionis-ing water consumption. Thanks to a new type of water distribution system with three infeeds, this toilet needs just 3.5 litres per flush cycle with excel-lent flush performance. With the additional econ-omy button, consumption can be reduced further still to just 2 litres.

Water-saving O.novo collection

With the O.novo collec-tion, Villeroy & Boch is offering a water-saving for projects of every size. The comprehensive range of toilets consists almost exclusively of water-saving models with AquaReduct technology (3/4.5 litre flushing)

0.8 litre siphon for urinals

Water-saving O.novo collection

3/4.5 litre Subway 2.0 2008

2011

2009

21

Product-related environmental protection

In addition to its bathroom series, Villeroy & Boch offers an extensive range of taps in a superb design. A highly innovative range of eco-friendly products is made at the Vargarda plant in Sweden, a leading sup-plier of taps and fittings in Scandinavia. This producer has been part of the Villeroy & Boch group of compa-nies since 2000. It distributes water- and energy-effi-cient fittings under the Gustavsberg brand, the “Col-

Chrome free production of tapsoric” range being a particular highlight. Its decisive advantage lies in the choice of material – aluminium – which makes the fittings lighter by two thirds, sig-nificantly reducing energy use, and thus emissions, for transport. A further advantage of using aluminium is that no environmentally harmful chrome at all is used during the entire production process. And finally, alu-minium is a sought-after recycling material.

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Product-related environmental protection

Other patented product innovations with a green im-pact from the Vargarda plant include innovative wa-ter- and energy-saving taps. A large number of product ranges are equipped with these solutions. When as-sembling such products, the water flow and/or water temperature can be regulated – according to the con-sumer’s requirements – via a pre-setting.

This means that when the tap is being operated, it initially opens only as far as the pre-set opening point so that the quantity and temperature of the

Drinking water – a precious commodity

Water saving

2000

1500

1000

500

0

m3 /w

eek

28 %31 %

38 %1435

1578

1903

Standard with eco effect with eco effect and Low-flow head

Energy saving

200

150

100

50

0

kWh/

wee

k

Standard

26

62

26 % 42 % 48 %

28

112

34

125

with eco effect with eco effect and Low-flow head

Cold water Hot water

A study of consumption in 65 apartments in Göteburg, Sweden (117 residents) confirmed by the SP Swedish national Testing and research institute Energy Technology, System and Ventilation Technology

WATEr SAVinG OF uP TO 40% AnD EnErGy SAVinG OF uP TO 50% COMPArED WiTH THE TWO HAnD MixEr

water are metered relatively low, but still at a pleas-ant level. However, if a greater quantity of water or a higher water temperature is required, the tap can be opened further by applying gentle pressure. As soon as the tap lever is released, the water volume or temperature is automatically regulated back to the pre-set volume.

Ultimately, this not only saves energy, but also in-creases comfort thanks to individual specification of a body-friendly water temperature.

55° C

≈ 43° CComfort temperature

≈ 10° C

Full flow

Comfort flow

Off

23

Applied research: environment and quality of life

Environmental awareness benefits not only nature and the environ-ment, but also results in a greater quality of life for us and our chil-dren. This is one of the most im-

portant goals to which Villeroy & Boch is

committed.

Applied research: environment and quality of life

The path to achieving this goal is primarily via research and innova-tion, both of which have been im-portant aspects of our corporate strategy for decades – even during the crisis. This is because progress on environmental issues goes hand in hand with strengthening com-petitiveness for an international ce-ramics producer. We have already outlined a number of important innovative achievements at various sites within the Group.

At its Mettlach plant in partic-ular, Villeroy & Boch has been able to build on its research expertise. It was here, for ex-

ample, that the energy-saving pressure casting technology was

developed, which saw the conven-tional shaping of products using

plaster moulds give way to pressure casting in resin moulds. The graph-ic on the right-hand side shows how energy consumption shifts, or is sig-nificantly reduced, when pressure casting technology is introduced.

Cross-sector research

This example documents our pro-duction know-how and process opti-misation that is orientated towards ecological sustainability. Since results combined with further research goals – external to Villeroy & Boch – can be made generally useful for ceramic

manufacturing processes, we have been working for a number of years with leading scientific institutes, aca-demic institutions and enterprises to achieve progress in environment-related areas. In the following pages, the spotlight is on comprehensive re-search projects conducted by Villeroy & Boch over a number of years with the support of the Federal Ministry for Education and Research (Bun-desministerium für Bildung und Forschung).

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Applied research: environment and quality of life – Dry-COnTrOll

DRY-CONTROL

New drying technology and process design for ceramic products

The objective of the project is to significantly increase the quality of products from the stone and earth industry by using targeted microwave drying and process-integrated, non-destructive testing methods, and thus bring about a marked improvement in raw material productivity.

This is based on the use of micro-waves, an area that has already been researched but about which little is known in the minerals industry.

Central to the project is the still energy-intensive drying of large ce-ramic parts such as toilets, the dis-advantage of which is that, with some parts, due to small damp ar-eas, cracks form in the firing process which can lead to the pieces having to be scrapped.

Special microwave sensory systems enable these damp areas to be de-tected and then selectively dried through targeted application of mi-crowave radiation. The end result should be reduced scrappage of pieces.

The increase in process safety that the project aims to achieve will be obtained using robots. A fully auto-mated robot system will detect damp areas and perform local microwave drying. This increases process safety and raw material productivity at the same time.

The Mettlach site is expected to see a saving of 1,550 tonnes of ceramic raw materials worth several hundred thousand euros (15,000 MWh of energy) and some 2,200 tonnes of CO2 emissions

Following essential changes and optimi-sation of processes, the focus is now on drying and the quality of semi-finished products.

iniTiAl SiTuATiOn

100

80

60

40

20

0Plaster casting Pressure casting

Preparation

Moulding

Drying

Glazing

Firing

67 %

18 %

4 %47 %

43 %

3 %

rESOurCE AnAlySiS OF A TOilET MODEl

OuTPuTinPuT

Gas: 170.43 KWhElectricity: 32.13 KWh

Emissions:CO2: 56 kgnOx: 103 mg/m3

HF: 2.7 mg/m3

Slip: 43 kg

Glaze: 4.3 kg

loss: 7.9 kg

recycling: 12 kg

loss due to firing: 2 kg

Wasser: 364,2 l Waste water: 159 l

Ceramic raw materials

Energy and water

25

Applied research: environment and quality of life – Or-C-EraM

OR-C-ERAM

Electricity recovery from waste heat

The aim of the project was to de-velop an integrated technology for energy and CO2 reduction.

The low temperature utilisation of waste heat was to be applied for the first time in the ceramics industry with the ORC (Organic Rankine Cycle) procedure.

Using the example of this project, both feasibility and efficiency were tested and demonstrated. This invol-ves unused waste heat in the tempe-rature range 220 – 260°C.

How does the ORC system work?The warm exhaust air from the coo-ling zone of a tunnel kiln is directed into the plant. In the ORC system’s direct evaporator, this waste heat helps vaporise an organic coolant and generate a pressure of around 25 bar. This steam drives a high-fre-quency generator coupled to a turbi-ne. Electricity is generated, fed into the Villeroy & Boch network, and consumed.

What is special about this ORC system?No other system in the world has a direct evaporator that operates in this performance range.

Most ORC systems to date operate in a performance range far above 100 KW. This system was developed for a performance of 30 KW.

When a test phase has been suc-cessfully completed, it is possible to transfer the findings gained from re-search and a pilot operation to other production facilities.

From left to right: CFO Villeroy & Boch AG, Jörg Wahlers, Environment Minister of the German federal state of Saarland, Dr. Simone Peter, and Dr. Wolfgang lust, Managing Director of ADATurB GmbH.

Even small energy savings produce both ecological and economic bene-fits.

This means a significant reduction in CO2 of some 4,500 tonnes per year – equivalent to around 10% of the previous CO2 emissions.

Apart from generating electricity, the heat produced by condensation of the coolant can also be used.

26

Applied research: environment and quality of life – SIMSan

SIMSAN

Scientific findings as a basis for optimising the production of sanitaryware

In sanitaryware production, ener-gy efficiency and productivity have been increased significantly in the manufacture of geometrically com-plex articles.

A key technology in this respect is moulding using the pressure cast-ing method, which in turn impos-es very high requirements of the quality of the ceramic raw materi-als used and of the slip produced. Fluctuations in the mineralogical composition, but also in the parti-cle size distribution and the particle morphology of the natural raw ma-terials used (such as with clays, kao-

lins and feldspars), can result in un-stable processes and, consequently, to scrappage of intermediate and end products.

The aim of the SimSan development project is to avoid the losses of ener-gy and resources and the CO2 emis-sions associated with it. A further aim is to now manufacture models – that could previously only be pro-duced in plaster moulds – using pres-sure casting based on recent innova-tions. This, in turn, would mean a considerable improvement in the energy efficiency of the production systems.

The raw materials and mineral sur-faces are examined using the latest analysis techniques, including X-ray diffraction and electron microscopy. On this basis, and supported by com-puter simulations of flow behaviour, optimised raw material compounds and slips are then developed. These enable trouble-free, robust process management with a greatly reduced loss of raw materials.

Implementation of this more en-vironmentally friendly production method strengthens the position of Villeroy & Boch in terms of cost savings thanks to the reduced ener-gy requirement and the associated reduction in the demand for CO2 certificates. Both economic and ecological benefits also come cour-tesy of savings in drinking water, raw materials, chemicals and land-fill volumes.

27

Applied research: environment and quality of life – KOMPlETT

KOMPLETT

Development of a key technology for water circulation and material cycles

Approximately 1.2 billion people do not have access to clean drink-ing water, while around 2.5 billion people have no access to sanitary facilities.

An ever increasing number of re-gions around the world will suffer from water shortages and poor wa-ter quality in future.

The provision of hygienically pure water will therefore become even more important in future, and will represent a major challenge facing the world’s industrial nations.

A project consortium, known as “KOMPLETT”, has set about ad-dressing this task. The objective of this project, which is promoted by the Federal Ministry for Education and Research (Bundesministerium für Bildung und Forschung), is the “development and combination of innovative system components from materials processing, information technology and ceramics to create a sustainable key technology for water circulation and material cycles”.

It is possible here to distinguish at local level between grey (for exam-ple shower) and black (toilet) water.

Both water flows are cleaned using newly developed procedures. The accumulated solids and urine mate-rial contained in the waste water are processed such that, depending on the initial conditions (countries, in-frastructure, geological conditions, regional drinking water supply/fa-cilities, prices etc.) and taking into consideration cost-effectiveness, it is possible to generate soil condi-tioners and/or energy. Depending on respective requirements, the water recovered is returned to the water circuit, for example to irrigate fields or to use as shower and bath water.

28

Applied research: environment and quality of life – KOMPlETT

The application potential is very diverse, covering:

l Arid areas and areas with low precipitation l Regions with bottlenecks in the water supplyl Remote regionsl Areas with high drinking water prices (a low-cost alternative to energy-intensive seawater desali- nation)

The project’s high degree of in-novation is based on two factors: firstly, all “potential recyclables” are actually recycled by taking the broader economic view. Secondly, the KOMPLETT system is large-ly independent of the supply and disposal infrastructure, which means that, for areas of the world that are dry and difficult to access, it represents an alternative to a cen-tral water supply and waste water disposal.

Part of this system includes water-saving systems and special sanitary-ware developed by a research group at Villeroy & Boch. The sanitary-ware features low water consump-tion and an antibacterial, sanitising effect.

The KOMPLETT project, which met with great acclaim at IFAT (the International Fair for Environmen-tal Technologies) held in Munich, was concluded with a demonstra-tion system in the German city of Oberhausen.

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Documentation of our environmental activities

Documentation of our environmental activities

EMAS is the acronym for the Eco Management and Audit Scheme. EMAS was developed by the Eu-ropean Union; it is a Community scheme comprising environmental management and environmental auditing for organisations that wish to improve their environmental performance. The EMAS directive (eco-audit directive) ascribes a cru-cial role to the individual responsi-bility of an economy to deal with its direct and indirect environmental

impact and relates to a specific loca-tion. Two Villeroy & Boch produc-tion facilities have been validated in accordance with the EMAS Guide-lines: Vargada (fittings) in Sweden

and Mettlach (sanitary factory) in Germany. The Torgau and Mer-zig sites in the tableware division are planning EMAS validation for 2012.

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iSO 14001ISO 14001 is an international en-vironmental management standard which defines globally recognised requirements for an environmental management system.It focuses on a process of continuous improvement as a means to achieve the respective defined objective in relation to an organisation’s environ-mental performance (companies, ser-vice providers, authorities etc.). The continuous improvement process is based on the planning-execution-monitoring-optimisation method.

The Saar Environmental Pact is a vol-untary agreement between Saarland’s state government and its economy to extend dialogue in the field of environ-

The following Villeroy & Boch sites have been ISO 14001-certified:l Mettlach (Germany) sanitary- ware factoryl Magyarország Rt (Hungary) sanitaryware factoryl AB Gustavsberg (Sweden) sanitaryware factoryl Nahm sanitaryware factory in Saraburi (Thailand)l AB Gustavsberg Vargarda (Sweden) fittings factory l Sanitaryware factory in Valence d’Agen (France) in November 2011

The Torgau and Merzig sites in the tableware division are planning ISO 14001 certification for 2012.

mental protection. Villeroy & Boch is party to the Saar environment pact, and operates proactively with various environmental projects.

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Occupational safety and preventive health

Occupational safety and preventive health

An important part of our environ-mental strategy also concerns our employees’ immediate workplace. Health and safety – in both produc-tion and administration – are at the heart of our activities. Here too, Villeroy & Boch has a tradition that dates back to the early 19th century.

We have systematically achieved continuous improvement in safe-ty management at the production sites. In addition to the legally pre-scribed safety measures, occupa-tional safety management focuses

on full prevention and a methodi-cal raising of awareness of occu-pational safety among employees. Employees are actively included in the determination and avoidance of risks. The success of this is evident from the accident statistics. For example, the number of accidents resulting in non-productive time ex-ceeding three days has been drasti-cally reduced at the sanitary factory in Mettlach, where no accidents at all have been recorded in the last three and a half years.

Health days in Mettlach: training exercise in first aid measures

32

As manufacturers of ceramic prod-ucts, we are aware that emissions generated by the use of additives have an impact on both the envi-ronment and occupational safety. Therefore, for example, we have not used any lead compounds in the production of sanitaryware for more than 20 years. The lead oxide still used in the ceramics industry is no longer used at Villeroy & Boch.

Fitness – an engine in life and at work

But health is more than just avoid-ing risks. It contributes to a general feel-good factor among employees – both at the workplace and in their leisure time. It is therefore a subject that Villeroy & Boch has focused on intensively. The first “health days” were held at the Mettlach site in 2010. All employees from production and management were invited to participate in the cam-paigns, including personal expert consultation. The aim was not only

to raise the level of awareness of health issues, but also, more im-portantly, to communicate methods for remaining fit and healthy at a practical level. The extensive ser-vices provided ranged from medical checkups, massage and back screen-ing through to workplace ergonom-ics, first aid measures, a driving simulator and an explanation of de-fibrillators for life-saving measures.

These health days were an enor-mous success, with over 450 em-ployees taking part. As a result, these campaigns were conducted at a further six sites in 2011, with each programme tailored to re-quirements. In Mettlach, the health days were held in conjunction with a small competition. The person recording the highest speed on the bicycle ergometer was rewarded with their amount in euros. The total amount raised by Villeroy & Boch was used for a children’s farm in Saarlouis, where young children can learn about nature – particular-ly animals – and therefore ultimate-ly learn to respect the environment through play.

Health days in Mettlach: training on the ergometer campaign “Driving for a good cause”

Children on the farm in Saarlouis interacting with animals – their favourite

playmates

33

Definitions

Waste:

Waste water:

AOX:

Process water:

CO2:

COD (Chemical oxygen demand):

EMAS:

Emissions:

R+D:

Fresh water:

ISO 14001:

Ageing:

Environmental Product Design:

Environmental Process Design:

REACH:

Rheological properties:

Pollutant:

Environmental impact:

Environmental index:

Saar Environmental Pact:

Environmental policy:

Environmental targets:

Definitions

All mobile objects that the owner wants to (or must) dispose of.

Water whose composition has been changed through domestic, commercial, industrial, agricultural or other use and that often contains harmful substances.

Absorbable, organic-bound halogens. Standard measurement for the pollution of a body of water or waste water with extractable halogen compounds.

Water that is not of drinking water quality, but may be used for industrial and commercial purposes.

Carbon dioxide; the main emission from thermal processes (in ceramic manufacture principally in the firing process).

Standard measurement for the quality of a body of water or waste water. COD covers the oxygen vol-ume required to break down persistent organic substances.

EMAS is the acronym for the Eco Management and Audit Scheme. EMAS was developed by the Eu-ropean Union; it is a Community scheme comprising environmental management and environmental auditing for organisations that wish to improve their environmental performance.

The air pollutants, noises, vibrations, light, heat, rays and similar environmental impacts generated by a plant.

Research and development.

Spring, well and drinking water.

ISO 14001 is an international environmental management standard that defines globally recognised requirements for an environmental management system.

Storage of ceramic slip to improve rheological properties.

Product development in which all economically, ecologically and technically realisable methods are considered in order to minimise the environmental impacts that arise over the life cycle.

Production process in which all economically, ecologically and technically realisable methods are considered in order to minimise the environmental impacts.

Registration, Evaluation, Authorisation and Restriction of Chemicals. A European Union regulation.

Deformation and flow behaviour of ceramic slips or suspensions.

Substance that has been generated by human activity, is released into the environment, and harms it.

All changes to the environment – whether of a positive or negative nature – that are the result, in full or in part, of a human or operational action.

Environmental data that focuses on a manageable number of meaningful key pieces of information. It enables the formulation of quantified environmental targets.

The Saar Environmental Pact is a voluntary agreement between Saarland’s state government and its economy to extend dialogue in environmental protection.

Environment related targets and operational principles of a company, including all relevant environ-mental regulations.

Specific, time-delimited company targets for operational environmental protection.

34

imprint

Imprint:Villeroy & Boch AG Environment/Safety/Research PO Box 1120 66688 Mettlach, Germany

Telephone: +49 (0)6864 81 1332 E-mail: krystkiewicz.danuta@villeroy-boch.com Web site: www.villeroy-boch.com Facebook: www.facebook.com/VilleroyandBoch Twitter: www.twitter.com/VilleroyundBoch

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Villeroy & Boch AGSaaruferstraße66693 MettlachGermany Web site: www.villeroy-boch.com