Environmental matters

Key environmental concerns for DEUTZ are environmental management systems, resource efficiency and climate. These are explained below:

Environmental matters form part of the integrated management system

DEUTZ AG’s integrated management system, which covers environmental protection, energy and quality, meets the requirements of the DIN EN ISO 14001, 50001 and 9001 (version 2015) standards that are currently applicable. This conformity was reviewed and confirmed by the external auditors from TÜV Rheinland Cert GmbH.

The continuous improvement process, which was introduced together with the integrated management system, helps DEUTZ AG to continually review the targets that it has set itself. This is done as part of the management review conducted by the Company’s most senior level of management (Chairman of the Board of Management). 

The senior management team is involved in the processes through the environmental management system. It assesses the measures as part of the management review and decides on further activities. 

Continuous reduction of emissions

The DEUTZ Group has set itself the target of reducing CO2 emissions per manufactured engine by at least 2 per cent. Data is also collected on the pollutants dust, nitrogen oxide and benzene; here too we are striving to continually reduce the level of these emissions per unit of production. 

Regular audits of energy use and environmental impact

DEUTZ AG has set up a working group to review its compliance with important product-related laws and regulations. The group conducts investigations into the supply chain, part of which includes auditing suppliers. In addition, internal environmental and energy audits take place five or six times a year as set out in the integrated management handbook. These are carried out in accordance with a fixed schedule and help to ensure that the examined processes comply with statutory norms and customer specifications. Most of the work is done by an external service provider that specialises in environmental and energy matters. The aim is to provide an assurance of legal conformity and to reduce commercial risk.

Reducing energy consumption

In early 2017, DEUTZ AG’s energy management system was recertified under ISO 50001 without any nonconformities. We continue to work on further developing this system in a continuous improvement process at strategic and operational level. 

Ongoing training for trainees/apprentices and production staff as well as optimisation of the measurement systems form the basis for identifying and successfully implementing measures to improve energy-related performance.

DEUTZ AG has adopted a variety of measures aimed at reducing primary and secondary energy consumption. It has achieved most energy savings by optimising its network of sites. 

Despite a sharp rise in production volume, the amount of energy used throughout the DEUTZ Group was reduced in 2017, by nearly 50 per cent in the case of district heating. Electricity consumption rose slightly for production-related reasons. Consumption of LPG was also higher due to production-related reasons, as this is being used to test the new gas engine.

DEUTZ Group: Energy consumption in our plants 1)
  2017 2016
MWh    
Electricity 84,605 79,837
Natural gas 35,277 35,795
District heating 12,223 23,017
Heating oil 2) 3,653 4,440
Diesel fuel 3) 19,218 20,144
LPG 4) 421 310
Total 155,397 163,543
1) Plants in the DEUTZ Group, excluding joint ventures.
2) At 10.5 kWh/litre (mean).
3) At 9.85 kWh/litre (mean).
4) At 12.8 kWh/kg (mean).

Minimising CO2 emissions through engineering

A number of different measures are in place to achieve the aim of reducing CO2emissions. At DEUTZ itself, emissions are primarily produced by the engine test bays used in development and production. The state-of-the-art, high-performance exhaust gas aftertreatment system used in the production test bays at the German sites ensures that DEUTZ remains within permitted limits and, in some cases, is well below them. DEUTZ AG is also introducing cold testing, a system in which comprehensive pre-start diagnostics are run on the engine functions. Some engines will therefore not have to undergo test runs for minutes at a time. This will conserve fuel and substantially reduce engine emissions. The test method, which offers compelling economic and ecological advantages, was purchased in the reporting year. The project will commence in the second half of 2018. Plans for the forthcoming optimisation of material flows for engine series with capacities of less than 4 litres include ramping up the proportion of cold tests of sub 4 litre engines at the Porz plant to more than 50 per cent by 2020. The cold testing has the potential to dramatically reduce factory-related emissions, which at DEUTZ AG are mainly released from the consumption of fossil fuels in test bays. 

Reducing CO2 emissions through sustainability

The optimisation of our network of sites, which was completed last year, is also playing a key role in resource efficiency. The clearing of the Cologne-Deutz premises at the beginning of 2017, with the site being sold and a new shaft centre built in Cologne-Porz, has freed up around 160,000 square metres of industrial space in a central location in Cologne. The area can be used for housing, commercial premises, schools and parks. As the Company’s utilisation of space is now much more efficient and old infrastructure has been disposed of, the energy efficiency of the network of sites has improved and the emissions they produce have been markedly reduced. And in mid-2017, the relocation of production from the Übersee plant on Lake Chiemsee to the Ulm plant was successfully completed – and it has had a positive impact in terms of both resource efficiency and emissions. 

When designing its workspaces, DEUTZ AG takes sustainability aspects into account as soon as planning starts. In our new shaft centre at the Porz plant, the supply of coolant has been centralised and the flow of materials optimised from an economic and ecological perspective. This has reduced the throughput time of camshafts by around 75 per cent and of crankshafts by more than 50 per cent. 

Reducing CO2 emissions through technology and innovative products

DEUTZ is further minimising emissions by introducing more stringent emissions standards for diesel engines and by optimising its products. In 2017, DEUTZ became the world’s first engine manufacturer to be given a certificate for the Stage V emissions standard, which comes into effect in the EU in 2019. Numerous engine models in the 3.6 litre to 7.8 litre power output range have now been certified. The Company has therefore met what will be the world’s strictest emissions standards ahead of time and is actively contributing to climate protection and improvements in air quality. DEUTZ engines offer high performance, a small installation space and, at the same time, reduced fuel consumption. This is to the benefit both of our customers and of the environment as CO2 emissions are directly related to fuel consumption. 

In recent years, Torqeedo has won multiple accolades for its innovative products and environmental credentials. For example, it received the Top Product 2016 award from US magazine Boating Industry for its Cruise 10.0 R outboard motor as a “green and quiet alternative for commercial and recreational users”.

DEUTZ’s Xchange product programme also plays its part in improving sustainability as having used engines professionally refurbished gives them an extended lease of life.

Significant reduction in CO2 emissions

The DEUTZ Group’s primary environmental target is to reduce CO2 emissions per engine manufactured by at least 2 per cent every year, and it did significantly better than this in 2017, cutting emissions by 18.5 per cent. This is mainly attributable to the optimisation of the number of sites in Germany, the construction of a state-of-the-art, energy-efficient shaft centre at the Cologne-Porz plant, the savings in diesel fuels in development and the greatly expanded production programme. The overall impact will soon be greatly enhanced by the introduction of cold testing, which reduces some of the test runs that engines have to undergo. 

The reduction in nitrogen oxide, dust and benzene emissions was mainly achieved by cutting fuel consumption in production areas at the Cologne-Porz plant 5).

5) Not checked by the external auditor.

 

DEUTZ Group: Annual CO2e emissions in our plants 1)
  2017 2016 2)
Tonnes    
CO2e emissions (Scope 1) 13,239 13,748
CO2e emissions (Scope 2) 38,012 39,325
CO2e emissions (Scope 3) 9,217 7,722
CO2e emissions (total) 60,469 60,795
 
Scope 1: CO2e emissions from diesel, natural gas, LPG and heating oil caused by combustion in our own facilities.
Scope 2: CO2e emissions relating to purchased energy (e.g. electricity, district heating).
Scope 3: CO2e emissions from air miles and CO2e emissions produced by the treatment of purchased water.
1) CO2e = carbon dioxide equivalents.CO2e emissions in plants in the DEUTZ Group, excluding joint ventures. CO2e figures are reported in accordance with the Greenhouse Gas Protocol and are determined by multiplying the energy consumed by the relevant emissions factor. Prior-year figures have been adjusted in line with the new calculation method.
2) CO2e figures for 2016 have not been checked by the external auditor.
DEUTZ Group: Emissions per engine in our plants 1) 2)
  2017 2016
Emissions per engine    
CO2e (kg) 353 433
Nitrogen oxide (kg) 0.18 0.22
Dust (g) 2.25 2.70
Benzene (mg) 76.8 84.8
 
1) CO2e = carbon dioxide equivalents.
CO2e emissions in plants in the DEUTZ Group, excluding joint ventures. The other data relates only to German plants. CO2e figures are reported in accordance with the Greenhouse Gas Protocol. Prior-year figures have been adjusted in line with the new calculation method. The ‘emissions per engine’ figure is calculated by dividing total emissions by the number of engines made. CO2e reporting includes all scopes.
2) CO2e figures for 2016 and all figures for dust, nitrogen oxide and benzene have not been checked by the external auditor.