Designing products for a smaller environmental footprint

We all recognize the need to curb emissions and reduce our carbon footprint to combat climate change. To this end, Konecranes has adopted a product development approach with a special focus on environmental aspects. The Design for Environment process has a clear-cut target: each new product design’s environmental impact must be reduced from that of the previous generation.

When new products or components are designed, improvements in their environmental footprint must be considered at the very start of the process – it is more difficult and costly to incorporate them at a later stage. The Design for Environment approach is applied throughout the entire development process, from start to finish.

When the product development process is started, the first thing to decide is the environmental target for that specific case. It can be reduced lifecycle emissions, higher energy efficiency or the recyclability of materials, among other things. The target needs to be concrete and measurable.

“There are many different factors that can have an impact on a product’s environmental performance. Materials are one of these, as is the product design itself. We apply lifecycle thinking and consider the environmental impacts that arise from the use of the product, the potential needs and possibilities for maintenance and modernization, and end-of-life options such as the recyclability of components or materials,” says Kati Palomaa, Manager, Sustainability and Analytics at Konecranes.

It's all about the data

As a part of Design for Environment process, the team uses a standardized Life Cycle Assessment method. It is no simple task, as it requires vast amounts of data and careful calculations. Carbon footprint data may be needed from several different sources, including the suppliers of different parts and components, and therefore obtaining it can sometimes take time. In addition to supplier data and its own calculations, the team uses data banks.

Ideally, one set of calculations would suffice to describe the environmental performance of a product. However, different customers use Konecranes’s products in different ways and in different environments. Therefore, the calculations must be based on the most typical product configuration and use profile while acknowledging that this does not apply to all use cases.

The development process may involve a single solution or component or an entire machine. The scope varies and so does the extent of calculations and analyses. Similarly, the impacts vary.

“Sometimes we work on larger products, sometimes with a single part. If we make an individual component’s carbon footprint 50% smaller, while it might only represent less than one percent of the entire machine’s footprint the impact is actually cumulative when you apply the process to more and more components and solutions. This is a path of constant improvement where every new design contributes to the overall environmental performance,” Palomaa says.

A good example of the successes already achieved with the Design for Environment approach is the S-series hoist. The new design, which has a synthetic rope, requires less materials and is lighter than the earlier model. It requires less maintenance and is also more energy efficient. The recyclability of the hoist’s packaging was improved through material choices, and due to its smaller weight, emissions from logistics are relatively smaller. According to the Life Cycle Assessment carried out for the new design, the climate impact of the hoist over its life cycle is nearly one-fifth smaller than those of a comparably sized traditional wire rope hoist.

Specialized team with a versatile skillset

In product development processes, the designers who know the products play a critical role, but they are supported by the Sustainability and Analytics team, which sets the environmental targets and analyzes the impacts of the choices made during the design process. It is also important to understand the environmental performance of the existing products upon which the team seeks to improve.

“We have a team of five people, and everyone holds a university degree in the field of technology: four studied environmental technology and one materials engineering. Knowledge of sustainability sciences and solutions, circular economy and lifecycle assessment is particularly important in our work. We are continuously increasing our product understanding, but the main product expertise lies with the development teams we work with,” Palomaa says.

Design for Environment supports emissions reduction commitment

Dedicating an entire team to shaving off percentage points from a company’s environmental footprint is no small investment. Is it worth it? Absolutely. Konecranes wants to do its best to help society reach its climate targets. The company has recognized that the majority of its climate impacts stems from the use phase of the products and the materials used in them. Therefore, product development is a natural area for focusing our efforts.

“Konecranes is committed to limiting global warming to 1,5C with its aligned science-based targets. The Design for Environment product development method supports the work to reach these targets in a material way. This is strategically important for the company. Customers also appreciate our sustainability efforts; we have many large, responsible customers who have their own sustainability agendas, and we are proud to be able to contribute to them through smart, resource- and energy-efficient technology and solutions,” Palomaa concludes.