SONY_Reducing CO2 from Logistics

Reducing CO2 from Logistics

Reducing the amount of energy consumed, the volume of greenhouse gases emitted and the number of cardboard & pallets used in the transport of parts and finished products is significant to reduction of the environmental footprint of products over their entire life cycle.

Sony is decreasing shipping weight by means of product weight reduction. At the same time, Sony is striving to optimize logistics supply chain efficiency by means of shrinking the size of packaging, improvement of loading efficiency and simplifying parts packaging and also to swtich to environmentally conscious modes of transport such as modal shift and joint transportation in order to achieve reduction of CO2 emissions and packaging materials used in logistics.

Japanese Energy Conservation Lawexpedite consignors to implement measures to reduce the environmental impact of logistics. In particular, companies designated as "special consignors", which has particularly large shipping volumes, are obliged to report energy used. Effectively from April 2010, Sony EMCS Corporation was designated a special consignor. Sony has reinforced its ongoing efforts to reduce the environmental impact of logistics activities to respond to this move.

Sony Supply Chain Solutions, Inc. (SSCS) is primarily accoutable for logistics of Sony Group, handling transport within Japan, the United States and Europe, and among international locations. In fiscal year 2008, CO2 emissions associated with the business activities of principal Sony Group companies totaled approximately 720 thousand tons. 

• Reducing the Environmental Impact of Logistics through the Reuse of Packaging
• Promoting Modal Shift
• Sharing Shipments in Japan

Reducing the Environmental Impact of Logistics through the Reuse of Packaging

(Updated on August 31, 2010)

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  LCD television (BRAVIA™ LX900 series): Increasing transport efficiency through reduced packaging
  Left: KDL-52W5 (2009 model)
  Right: KDL-52LX900 (2010 model)

Within Sony Group, product design, procurement, manufacturing and logistics departments are working together to promote a packaging improvement initiative to realize optimization of total costs -- i.e., costs for design, procurement, manufacturing and logistics -- for products and components, and it is concurrently to reduce environmental impact of CO2 emissions and packaging materials used.

During the course of product package improvement, product loading efficiency to container is increased by shrinking package sizes and optimization of loading efficiency depending on transportation variation, thus, it shall contribute to reduction of environmental impact. As a typical example, packaging volume for LCD television sold in fiscal year 2009 was reduced by an average of 23% in comparison with models sold in previous fiscal year , thus CO2 emissions were reduced by an average of 26%.*

*The data is estimated based on assumption that 2008 model W5 series and eight models in the 2009 model LX-900, NX-800, HX-900 series are referenced and transportation distance is assumed that approximately 450 km from the factory, which is loaded on a domestic transport trailer (CO2 emissions per liter of diesel fuel is assumed to be 2.6 kg.)

Besides above efforts Sony has reduced packaging material usage by utilization of returnable containers. Sony began using returnable container in Japan in 2005; however, by relocation of production facilities to offshore in fiscal year 2009, Sony is currently utilizing their use primarily in Asia, where in August 2009, returnable containers were introduced for the shipping of products and components between Sony EMCS (Malaysia) Sdn. Bhd.'s Kuala Lumpur TEC and Sony Technology (Thailand) Co., Ltd.

In fiscal year 2009, Sony used approximately 12,000 returnable containers in Japan and overseas and it has contributed to reduce 571 tons of packaging materials and conventional pallets.

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  Structual concept of Returnable Container

Returnable containers are designed to meet efficient loading to sea freight container. In fiscal year 2009, Sony introduced modular size (standardized) cartons which effectively fit into returnable containers. Combination of different modular cartons which is suitable for size of individual components has increased component storage space in a returnable container and it, enabling Sony to maximized quantity of components per shipment.

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  Returnable container packed with modular cartons and shipping container efficiently loaded with returnable containers

Promoting Modal Shift

(Updated on August 31, 2010)

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SSCS is shifting from truck to rail and sea transport, both of which could reduce CO2 emmission for product transport than trucks in Japan. As an example, since 2000, Sony has started to share rail transport with other companies between Tokyo and Osaka by use of designated containers.

In fiscal year 2009, Sony utilized modal shift transport of approximately 21,100 tons of products in Japan, which resulted in reducing CO2 emissions by approximately 2,650 tons compared with conventional transport by truck. This amount is equivalent to approximately 24.2% of the volume of truck transportation in Japan.

SSCS is also promoting modal shifts outside of Japan. In Huanan County, in the People's Republic of China, SSCS shifted shipping containers from truck to rail for transporting products between its factory and port in order to reduce CO2 emissions.

Sony Brasil Ltda. has shifted product transport from truck to ship from factory in Manaus to São Paulo.

In France, Sony has shifted transport from truck to barge ship from Le Havre bound for Éragny in the suburb of Paris, and also to rail for product transport which is bound for the South of France in order to reduce environmental impact.

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  Shifting from truck to barge ship and rail for product transporting goods in France
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  Modal shift from truck to ship in Brazil

Sharing Shipments in Japan

(Updated on August 31, 2010)

SSCS has promoted the sharing of shipments with other companies since 2007,. Having already introduced this operation in Hokkaido, Okinawa and Fukuoka in February 2010, it was expanded its application to Osaka. In addition to sharing shipment to increase loading efficiency, it makes it possible to consolidate truck loading. In fiscal year 2009, the consolidation of truck loading by operation above could lead to reduction of approximately 91 tons of CO2 emissions.

判斷是否翻新機重上熱收縮膜的一個檢驗方法

判斷是否翻新機重上熱收縮膜的一個檢驗方法
經本人長期觀察美國原裝機發現，所有的原裝熱收縮膜上，在機盒側面位置（寫iPhone和容量的那面），會有兩個直徑為１毫米的隱蔽小孔，小孔的作用是在過熱機的時候釋放收縮膜內部空氣，以達到收縮膜包裹產品的平整，原裝機收縮膜上的兩個小孔位置是上下對稱的，這應該是機械打的孔，由於本人未見過翻新機，猜測一般的翻新機由於工藝簡單，熱收縮膜上的小孔多為人扎，不會上下位置對稱，（我自己的工廠三百多號人打熱收縮膜，也是手扎的，我不相信搞翻新機的規模比我的還大）還請大家在選擇三碼合一時擦亮眼睛．

LLDPE拉伸膜之認識

LLDPE拉伸膜之認識

LLDPE拉伸膜之認識

前言：
LLDPE拉伸膜，簡稱PE膜，又叫纏繞膜、工業用保鮮膜或棧板膜，國內最早以PVC為基材，由於環保問題、成本高、拉伸性差等原因，當90年代國內開始生產PE拉伸膜時逐步被淘汰。早期LLDPE拉伸膜以吹膜為多，從單層發展到二層、三層、五層；現則以流延法生產LLDPE拉伸膜為主。

功用：

LLDPE拉伸膜，主要用於零散商品進行集合包裝，代替小型集貨箱，方便於運送、產品的防潮、防溼、防塵等。LLDPE拉伸膜不能用於食品用保鮮膜，雖屬同類，然配方不同，加熱會有有害物質產生。

國內目前有做拉伸膜的公司只有五家，井菖、厚森、岡韋、順昶、南亞，其餘品牌不是委託代工或是從馬來西亞或中國進口。井昌與厚森的PE膜走低價的路線，品質與後三家稍差，然仍有其慣用客戶，特別是井菖，他是用吹膜的機器生產，產品可以用但是非常黏，但價格也是最低的。岡韋是國內唯一擁有五層共擠設備的公司，最近的技術跟品質都較之前穩定很多，有愈做愈好的感覺。順昶也是一家老廠商，是台聚的關係企業，在國內外都有許多的工廠，不過好像在台灣有很多的伸縮膜都是他們從馬來西亞的工廠進口進來的。南亞是賣牌子的，它的售價最高，市場上手持式纏繞膜一般為17μm，但是由於貴、且品質被認定較好，為競爭常使用16μm纏繞膜，使拉近價格與他牌差不多。近期因塑化原料大漲教育使用15μm纏繞膜。

拉伸膜的應用形式

密封包裝　這種包裝類似於收縮膜包裝，膜繞著棧板把棧板全包起來，然後兩個熱抓子把兩端的膜熱封在一起。這是纏繞膜最早的使用形式，並由此發展了更多的包裝形式如下。
全寬包裝　這種包裝要求膜寬足够覆蓋棧板，棧板的形狀規則，所以使用起來有它的局限性，適合薄膜厚度為17～35μm。
手工包裝　這種包裝是纏繞膜包裝中最簡單的一種，膜裝在一個架上或由手持，由棧板轉動或膜繞棧板轉。主要用在包好的棧板破損後的重新包裝，及普通的棧板包裝。這種包裝速度慢，適合的薄膜厚度為15～20μm。
裹膜機械包裝　這是一種最普遍最廣泛的機械包裝形式，由轉盤旋轉或膜繞轉盤旋轉，薄膜固定在支架上可上下移動。這種包裝能力很大，每小時约15～18盤。適合的膜厚约17～35μm。
卧式機械包裝　不同於其它包裝，由膜繞著物包品轉，適合於長的貨物包裝，如地毯、板材、纖維板、異形材等。
紙筒的包裝　這是纏繞膜的最新用途之一，比起老式的紙筒包裝用纏繞膜包裝更好。適合的膜厚為30～120μm。
小物品的包裝　這是纏繞膜的最新包裝形式，既可以减少材料消耗，還可以縮减托盤的存放空間，在國外，這種包裝最初介紹於1984年，僅僅一年後，市場上就出現了許多這的包裝，此包裝形式具有巨大的潛力。適合膜厚15～30μm。
管和電纜的包裝　這是纏繞膜在特殊領域應用的一個例子，包裝設備安裝在生產線的最後，完全自動拉伸膜既可以代替帶子捆住材料，又可以起保護作用。適用的厚度15～30μm。

裹膜機包裝的拉伸形式：

拉伸膜的包裝都須經過拉伸，裹膜機包裝的拉伸形式有直接拉伸和預拉伸。預拉伸又分為兩種，一種是軸預拉伸，一種是電動拉伸。
直接拉伸是在轉盤與膜之間完成拉伸。這種方法拉伸倍率低(约15％～20％)，若拉伸倍率超過55％～60％，超過了薄膜原有的屈服點，膜寬了减少了，穿刺性能也損失掉，膜很容易斷。且在60％拉伸率下，拉力還很大，對於輕的貨物，很可能使貨物變形。
預拉伸都是由僅次於膜卷的兩根軸完成。軸預拉伸的兩根軸是由齒輪單元連結在一起，拉伸倍率可以依齒輪比不同而不同，拉力由轉專產生，由於拉伸是在短距離内產生，軸和膜之間的摩擦力又大，所以膜寬不縮，薄膜原有的穿刺性能也保持下來了。實際纏繞時没有拉伸發生，減少了由於尖銳的邊或角造成的斷裂，這種預拉伸可以使拉伸倍率提高到110％。
電動預拉伸的拉伸機理與軸預拉伸相同，不同的是兩軸由電動動，拉伸完全與轉盤的轉動無關。所以適應性更强，輕的、重的、無規則的貨物都適用，由於包裝時張力低，所以這種方法預拉伸倍率高達300％，大大地節約材料降低成本。適合膜厚15～24μm。
綜上所述，拉伸膜的應用領域非常之廣，而國内很多的領域還未涉及，已涉及的許多領域也未普遍使用，隨著應用領域的擴大，拉伸膜的用量必將大大增長，其市場潛力是不可估量的。所以我們有必要大力推廣拉伸膜的生產和應用。

資料取自：林淵智　史鳯烟先生合著LLDPE拉伸膜、Andy補述LLDPE拉伸膜之認識

POF收縮膜

POF收縮膜

POF收縮膜( POLYOLEFIN HEAT SHRINKABLE FILM)又稱三層共擠壓膜或環保收縮膜，POF收縮膜為先進的收縮膜；結構為上、下層PP材質，中間層為PE材質。
POF收縮膜於民國80年代初源於義大利，產品的主要特點是：
1.透明度高、光澤性好。
2.柔韌性好，使用方便。
3.收縮率大，收縮率最高可達70%。
4.封合性佳、強度高、適合手動、半自動和高速全自動封口包裝機械。
5.耐寒性好，可在－40℃保持柔韌性而不發生脆裂，適合被包裝物在寒冷環境下儲存和運輸。
6.環保無毒。符合美國FDA標準，可包裝食品。
7.防潮防塵。
8.包裝成本低，優於紙盒及其它材料包裝。
POF收縮膜廣泛運用於食品、影音書籍、電子資訊、文具五金、工具日用品、藥品以及化妝品等行業，在現今歐、美、日等發達國家，POF收縮膜已廣泛的應用，並迅速成為國際上熱收縮膜的消費新寵。
目前市場上熱收縮膜有PS收縮膜、、PP收縮膜、PET收縮膜、PE收縮膜、PVC收縮膜POF收縮膜，後四類為市場常見收縮膜；而在熱收縮膜這個大家庭裏，POF熱收縮膜將是逐漸興起並將他類收縮膜替換的收縮膜。

MD:縱向收縮率 TD:橫向收縮率

Top ten trends for 2011

Top ten trends for 2011

As we approach the close of 2010, Packaging Magazine predicts some of the trends and changes facing the industry for 2011.

1)      Importance of design: As the part that communicates directly with the consumer, the importance of design should never be underestimated. Understanding the market and understanding the customer you are trying to attract is a key.

2)      Life cycle analysis: Demand is increasing for manufacturers to consider environmentally friendly practices for every facet of their operation. Energy saving, water saving, material reduction, recyclability are just a few of the considerations involved with a LCA.

3)      The robotic age: Automated technology is improving all the time and with post-GFC companies’ alert to methods of lowering costs while upping production, robots are becoming an increasingly familiar feature in the packaging process.

4)      Digital printing: Individual customization, shorter production runs, flexibility and rapid turnaround are just a few of the benefits of digital printing. Digital printing has been gathering momentum for a few years and 2011 will see in an increase in versatility and application.

5)      Shrinking packaging: less is more in packaging, with thinning, lightening and generally reducing of packaging materials.

6)      Labeling revolution:  An overhaul of food labeling policy will take place in 2011, which will probably result in dramatic changes to the labeling process.

7)      RFID tagging: tracking products across the supply chain is taking off in a big way. It provides security and authenticity and will become a common feature of the labeling of products.

8)      Portion size: Consumers are demanding a great choice when it comes to portion size – the packaging industry will need to be flexible enough to adapt to these changes.

9)      Disposability and recyclability: With a number of new bio-plastics and paperboard products appearing on the market and an increasing push for glass bottles, 2011 will see a great drive towards biodegradable and recyclable packaging products.

10)  Customization: Companies are beginning to ask more of packaging manufacturers, particularly for unique, customized designs.