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The Environment
Living as a member of a global community it would be irresponsible for us to ignore some of the environmental challenges that face the world today. Climate change and the impact human activity has had on natural resources have become a very real concern for us at Adcock Ingram. South Africa's hosting of the UN Climate Change Conference (COP17) discussions in Durban at the end of 2011 indicate positive strides towards reaching a legally binding global agreement on reducing carbon emissions and the handling of the impact of climate change.

Adcock Ingram is committed and willing to work with the national governments within all the regions where the company has operations to make a positive contribution to their efforts to combat the impact of climate change. It is undisputed that this impact will have a direct effect on the health of people and therefore on the business. Adcock Ingram believe the company is in a unique position to provide value in this regard.

As a conscientious organisation Adcock Ingram has given increased focus to elements such as energy, water usage and waste management. Many other considerations are incorporated as part of daily business activities.

In the last year Adcock Ingram recognised the need for an environmental policy. This is in development and will be submitted to the board of directors for approval.

Health and Safety Audit


Health and Safety Audit ScoreTarget for Year Under ReviewTarget for 2012
R & D98 %95 %95 %
Clayville96 %95 %95 %
Wadeville96 %95 %95 %
New Road, Midrand98 %95 %95 %
Critical Care92 %95 %95 %
15th Road, Midrand96 %95 %95 %
Durban98 %95 %95 %
Port Elizabeth98 %95 %95 %
Cape Town97 %95 %95 %
Bloemfontein98 %95 %95 %

Environmental Control System Audit Results for Adcock Ingram Sites


Environmental Control System Audit ScoreTarget for Year Under ReviewTarget for 2012
Wadeville94 %90 %90 %
Clayville93 %90 %90 %
Midrand distribution center92 %90 %90 %
R & D96 %90 %90 %
Aeroton91 %90 %90 %

Looking Forward


"To position Adcock Ingram as a benchmark healthcare company, that has fully internalised and implemented a cutting edge Sustainability Strategy by considering the economic, social, environmental and financial issues in context in which we operate both now and in the future."

The commitment to a formalised environmental programme has been championed by the CEO and the responsibility for this program has been assigned to senior executives within the supply chain and financial functions. Regular reports will be provided at executive and board meetings and progress will be measured against defined targets.

Several new manufacturing projects have been undertaken during 2010 and will continue into 2012. Inherent in each of these projects is a commitment to implement and utilize environmentally friendly initiatives in order to continue on the path to becoming a more environmentally aware and compliant organisation.

Over the next year, Adcock Ingram intends to empower staff on a variety of sustainability issues through internal awareness campaigns. The awareness campaigns will aim at behaviour change. This will be in conjunction with changes within the working environment to facilitate the behaviour change where possible.

In addition, the company is looking at ways to collect and collate more detailed information of various consumables in a manner that will add value to the assessment and improvement of processes and procedures as well as facilitate additional disclosure. A combination of these efforts will have both a cost and resource saving impact.

Climate Change
The anthropogenic impact on climate change is without question. The uncertainty relates to the extent of the impact. The South African government has stated their intent to reduce carbon emission by 34 % on business as usual scenario by 2020 and by 42 % by 2025. This however is conditional on attaining financial and technical support from the international community.

At Adcock Ingram, there is a belief that the company is making constructive contributions to these efforts. An increased focus on climate change and other sustainability issues has become more prevalent in the way the company conducts its business. Adcock Ingram believes that this is the beginning of the journey and the business is glad to report that throughout the company there is increasing evidence of efforts by employees to make a positive impact on these issues. Adcock Ingram now has dedicated resources focusing on sustainability considerations, including the issue of climate change and other environmental, social and financial considerations and implications.

Adcock Ingram has also increased its involvement in workshops and discussion groups looking at climate change over the last few months of the financial year. The UN Climate Change Conference (COP17) taking place in Durban at the end of 2011 was an ideal opportunity for businesses in South Africa to show its commitment and support in addressing this global issue and demonstrate their efforts to operate as more conscious businesses.

Carbon Footprint
In a world where the impact of business on the environment, direct or indirect is of fundamental importance, Adcock Ingram have become increasingly aware of the company's activities and their implications for all stakeholders. Over the last few years measuring Adcock Ingram's carbon footprint has allowed the organisation to gain a better understanding of operational emissions. This is only a start. The business is using the findings of the carbon footprint conducted as at 2010 financial year end as the base year. The footprint was done by Global Carbon Exchange, and independent vendor.

Environmental Control SystemFinancial Year Ended
30 September 2011
Financial Year Ended
30 September 2010
TonnesTonnes
Scope 1
Company-owned/controlled vehicles5 22717 303
Stationary fuels10 04910 918
Fugitive emissions (Kyoto)57133
Other (non Kyoto gases)1 7431 571
Scope 2
Electricity32 45627 744
Total Scope 1 & 2 and Other49 53257 669
Scope 3
Business travel7 3407 946
Employee commute4 6873 518
Outsourced distribution (import)8 91918 254
Outsourced distribution (export)1 190549
Packaging materials26 1838 623
Paper use2846
Waste8 1345 254
Water (embedded CO2e)277516
Total Scope 356 75844 706
Total106 290102 375
Tonnes Per Employee19.0128.37

Carbon Disclosure Project (CDP) and Water Disclosure Project (WDP)
In the last year Adcock Ingram once again worked with Global Carbon Exchange to facilitate Adcock Ingram's response in the CDP. This process as always is one of introspection and essential findings on Adcock Ingram's efforts in terms of the company's carbon considerations from both a risk and opportunity.

In the year under review Adcock Ingram willingly participated in the WDP. This has not been rolled out to all JSE Listed companies but as a water conscious business Adcock Ingram appreciates the need to evaluate and monitor usage and disposal of effluent. The company's participation has highlighted the need to keep more detailed information on water.

Water
There is no doubt that this natural resource is fundamental to Adcock Ingram's business. The availability of usable water will impact on the sustainability of the company. With this acknowledgement Adcock Ingram have become increasingly aware of the management of this scarce resource. The company is investigating ways to limit waste water and looking at innovative ways of saving on this resource as well as costs in the long term. Adcock Ingram will aspire to enhance the current management processes and report progress on more efficient usage of this precious resource.

Some of Adcock Ingram's efforts include:
  • The use of grey water for irrigation
  • Recycling brown water for use in lavatories
  • Borehole water is used for irrigation
  • Constantly looking at ways to improve recycling water at the plants
Case Study: 5-litre Can Project

This project was undertaken as the cleaning process resulted in water remaining in the container due to the nature of the handle on the can. An investigation was conducted and a new design developed by employees with a design house.

Benefit Measurements

Primary Metrics: Cycle time
Current units: 1 800 units/shift
New design will increase outputs by 27 % (2 300units/shift)
Speeding up of the rinsing process will reduce the cost of the product by R2.80 per unit
Total Annual Savings = R2.5 million (R2.80 x 0.9 million units p.a)

Secondary Metrics: Cost of new can
Current Price: R5.55 each
New Price: R4.30 each
Savings: R1.25 per can
Total Annual Savings = R1.1 million (R1.25 x 0.9 million units p.a)
Total Savings = (cycle times savings + cost reduction on new can) = R3.6 million p.a

Potential Additional Savings
  • The new can will require a new cap as well. Currently negotiating lower prices. (Estimate savings in the region of R45 000 p.a)
  • Overtime and weekend work will be stopped (labour cost saving)
Adcock Ingram's Critical Care Division trounced all other national contenders to take first place - Gold - in the Corporate Division of the annual Productivity Awards in October 2011.

Energy
Without a doubt this is a key consideration for all businesses, particularly in South Africa in recent years. Adcock Ingram has reviewed a number of initiatives to reduce energy consumption throughout the business. This covers a range of processes and is ongoing. These efforts are increasingly conducted from a more coordinated manner within the business. Adcock Ingram has started an energy audit to establish a baseline for the company's consumption at a number of the sites. This will allow a more focused approach on how to reduce energy consumption in certain processes, resulting in less carbon emissions as well.

Some of Adcock Ingram's efforts include:
  • Energy reduction efforts are on-going with constant evaluation and assessment
  • Commissioning of an energy audit to establish a baseline
  • Using energy efficient lighting in new developments or in retrofitting
  • Consideration of solar energy for emergency lighting
  • Implementation of energy saving initiatives at the Durban distribution centre
Case Study: The Quest for Energy Saving

Creative energy thinking resulted in 49 % saving in energy, an estimated R2 million saving in energy costs at the Midrand Distribution Centre over five years. It also resulted in a saving of R8.5 million in capital expenditure. The project team earned a Green Supply Chain Award for the best energy saving project over R10 million for this fine effort.

Adcock Ingram's national distribution centre in Midrand is the core of the Group's national supply chain. MCC regulations require that the 8 000sqm high rise warehouse be air-conditioned to ensure optimal storage conditions for Adcock Ingram products. This required inter alia, temperatures remaining between 18 – 25 deg.

Professional consultants provided estimates which illustrated that the total power requirements for the site would be 1 800 kVa against the total incoming, poor power supply of 1 000 kVa – this at the time when South Africa was experiencing its worst ever energy problems. Eskom advised that it would take 3-5 years before the incoming power supply could be increased to required levels.

The project team was therefore faced with a crisis and a desperate need to halve the estimated power demand without compromising on air-conditioning (the major power consumer on the site), lighting and other energy shortages.

Extensive research led to the discovery of a 'variable refrigerant volume' (VRV) system commonly used in Japan for office cooling (never in a warehouse application). Estimates showed that the VRV system for the warehouse (coupled with insulation improvements) would reduce air-conditioning demand from 800 kVa to 350 kVa. The building was made airtight and the warehouse roof was lifted and Rock Wool insulation inserted under the sheeting. This contributed to a 20 % reduction in air-conditioning power requirements.

Traditional warehouse lighting was replaced with T5 fluorescent lights connected to passive infra-red sensors. The latter turned off the lights when there was no movement in the area.

A change to high frequency charges reduced the power requirement for charging batteries by 15 %. Multiple batteries were introduced to allow charging in non-use periods.

A building management system was installed to manage all energy components of the warehouse and office block. This included air-conditioning, temperature control and monitoring, peak power demand, access control, security and use of the generator.

This case study illustrates that significant benefits can be achieved based on a simple, aggressive approach and 'out of the box' thinking as traditional techniques are not necessarily the best options when saving energy is a priority.

With acknowledgement to Industrial Logistic Systems, Daiken and Johnson Controls.

Waste Management
There is a highly developed waste management process in place at the Aeroton site. This has been running for a number of years with continual improvement made to the process. Recycled materials are cardboard, pallets, plastic and steel. This process has resulted in the commissioning of a dedicated resource to assist in the maintenance of this operation. There are specified vendors, pre-approved to remove the waste. Waste is weighed and an invoice is sent to the respective vendor.

Adcock Ingram has become increasingly aware of the waste generated through the entire lifecycle of the products. The company is looking at the process from cradle to grave and exploring ways that we could possibly limit the environmental impact.

Some of Adcock Ingram's efforts include:
  • Having generated income of almost R600 000 from waste recycling
  • Having developed a dedicated waste management site at the Midrand offices
  • Looking at the nature of product packaging
Distribution
Adcock Ingram's distribution business received the Best Project over R10 million Award at the Green Supply Chain Awards in August 2011. This was based on energy saving efforts undertaken by re-engineering building, lighting, air-conditioning and incoming power supply infrastructure, operational processes and management systems. This resulted in a reduced overall demand to below 800 kVa, in comparison to the estimated 1 600 kVa required, half the expected power requirement, as calculated by engineers, at the Midrand distribution site.

In November 2010 similar applications were undertaken at the Durban distribution site. Lighting and air-conditioning were adapted. Adcock Ingram is looking at the viability of rolling out some of these initiatives at other distribution sites.

Adcock Ingram is aware of the pending carbon tax and is looking at how this will impact operations, particularly from a distribution perspective and how this can be managed.

Since May of 2011 there has been greater consolidation of Critical Care, Pharmaceutical and now NutriLida deliveries. This has resulted in fewer delivery trips and therefore less carbon emissions.

Critical Care has been integrated into Pharmaceuticals distribution centres to facilitate the consolidation and improve distribution to customers. This has not resulted in any system changes and Adcock Ingram believe the company will see additional reductions in carbon emissions in the next financial year. The 15th Road site is due to cease operating within the next financial year. The links between this site and Midrand required numerous trips which will no longer be needed. This will again contribute to carbon emission reduction efforts.

When negotiating contracts with distributors Adcock Ingram undertakes a thorough review. The company focuses on the vendor's replacement policy which incorporates issues such as fuel efficiency, maintenance, vehicle selection criteria and impact on terrain. Adcock Ingram also focus on speed and percent of driving that takes place in the "Green Band" (this is the range in which a vehicle is the most economical).

Adcock Ingram is looking at developing a new distribution centre in Cape Town. The company is looking at incorporating a number of green elements in the development of this site.

Administration
Adcock Ingram's Human Capital department has invested R29 640 in an electronic system allowing employees access to their payslips and other relevant information electronically. This system allows access to historic data and is available to all employees who have access to a computer. Not only will this result in financial savings, but will also have a significant impact on the amount of stationery used for communication from the Human Capital department. Environmentally there will be a reduction of paper use.

Midrand Head Office & Warehouse Facility


A number of energy, water saving and waste management initiatives have been implemented at the site and are inherent in the design of the original building. These include:

  • A Building Management System (BMS) with an intelligent energy management system control which manages the overall energy usage on site. Savings through this system are estimated to average more than 30 %. Elements of this BMS system that contribute to the savings are the energy manager (controlling energy consumption and peak loads by switching off equipment at critical times without compromising functional standards in the building), timers (controlling air-conditioners, geysers and lights) and intelligent control systems that ensure that the distribution warehouse is controlled to strict Medicine Control Council (MCC) temperature standards
  • This BMS system also offers a comprehensive monitoring system to track water usage, electricity usage, critical alarms on equipment like the generator, fresh air systems, fridges, freezers, fire systems, access control, alarms and air-conditioning systems. This is monitored on a 24/7 basis in the central control room
  • Insulation was installed (to cover the total roof surface). An estimated savings figure from the engineer/manufacturer is stated as
    40 %
  • The front of the building has trellises to aid cooling in the main office building and creepers have been planted to grow up these trellises
  • Rain water is channeled into containment/drainage ponds. This ensures better flood control and water is also fed back into the groundwater system. Rain water catchment project is looking at taking water from the roof and parking areas into the rainwater catchment pond. An automatic drain pump will send water for irrigation when it reaches a certain level. Adcock Ingram will look at developing an additional pond for this at a later stage
  • A rain sensor installed on the irrigation control system ensures that water is saved when it is raining
  • The borehole on site contributes to water savings
  • The warehouse is equipped with motion sensitive lighting control
  • The auditorium and boardroom lights and air-conditioner are controlled by motion sensors
  • In the process of installing heat pump technology to replace geysers' element heating. Expected savings will vary between 75 % and 85 % (depending on air temperatures around the heat pumps)
  • More than 80 % of the fluorescent lights in the building are controlled by electronic starters (leading to lower energy usage and higher globe-life expectancy). There is an ongoing drive to replace the balance of old ballast systems with electronic starters
  • There is a process in place to ensure that fluorescent lights are disposed of according to strict prescribed environmental process
  • The diesel tank system on site was also built in accordance with strict local authority environmental rules (bund walls to control spillage/leakage and fire protection system) and the necessary certificates are being renewed on an annual basis
  • Flat screen technology (as opposed to CRT) is used on all computer terminals
  • Technology drives numerous electronic office initiatives
  • Paper and other waste recycling initiatives are in place
  • As a new initiative a waste sorting section has been constructed to facilitate in waste management. This will result in waste sorting within the warehouse as well. This will be rolled out in the new financial year
  • With the arrival of the Gautrain a number of employees have chosen to use this mode of transport to get to work. There will be a pedestrian gate built to allow staff easier access to the building
  • Initiatives have been taken to reduce the impact of the noise levels from the warehouse on the neighbours. A wall has been constructed around the refrigeration plant
  • Quarterly fogging is conducted in the building using environmentally friendly chemicals
  • All cleaning materials used are environmentally friendly
  • Plans to develop a herb garden to provide for the canteen on site
  • A road was built in order to avoid destruction of a wetland that exists behind the building
  • The koi pond was temporary relocated in order to preserve the fish and plant life. The fish will be returned to the permanent ponds on completion of the construction
  • Looking at the viability of solar panels to support emergency lighting
Midrand Head Office & Warehouse Facility
Midrand Head Office & Warehouse Facility

Clayville Manufacturing Facility


As this is a new facility, many environmental initiatives have been inherent in the design and equipping of the facility:

  • Process HVAC (Heating, Ventilation, Air Conditioning and Cooling) design is on the basis of maximal energy efficiency while achieving regulatory demands for pressure cascades and clean room conditions. Use is made of physical and computerised design elements driven by a complex Building Management System to ensure minimal or no energy consumption during production downtime
  • Energy saving lighting design is applied throughout the facility with a range of energy efficient lighting applications deployed depending on the purpose of the various areas.
  • Provision is made for recovery of process effluent through a self contained effluent pit to hold contaminated water for treatment and safe disposal
  • A Geothermal heat exchange system will power the air conditioning for both the office and warehouse components of the project, reducing the consumption of electricity to only the difference between the constant 18 degrees supplied by ground and the 23 degrees Celsius state to be achieved in warehouse and offices
  • Process water (reverse osmosis) will be recycled for domestic use – basins, drinking water, toilet flushing and gardening water will all be from the purified water process run off
  • Manufacturing process equipment and methods have been reviewed and the most energy efficient technologies and methods have been applied wherever possible. Process automation will ensure that process times are minimised and consistent, there is little room for discretion and consequently process variation is minimised
  • Solar power will also be implemented for dock levellers and weighbridges

Wadeville Manufacturing Facility


A new office facility and extension to the factory was added in 2009 with many electricity and water saving initiatives being implemented at the same time:

  • Motion sensitive lighting has been installed throughout the office building
  • Tinted glass has been installed on the office buildings to assist with temperature cooling
  • Air conditioning in the office block is controlled by motion sensors
  • The transformer ballasts of fluorescent lights have been replaced with electronic ballasts, using less energy
  • Solar heating for the canteen geyser has been installed
  • External flood lights are controlled by day/night switches
  • Light dimmers have been installed in the boardroom and training room
  • Power factor correction has been installed in all three substations
  • The Air Handling Unit (AHU) and compressors are fitted with variable speed drives to control the speed of operation depending on demand

Bangalore Manufacturing Facility


In 2008, Adcock Ingram entered into a JV in India and built a new PIC compliant tablet and capsule manufacturing facility which offers the following environmental benefits:

  • Motion sensitive lighting has been installed throughout the facility
  • More than 50 % of lights are Compact Fluorescent Lamps (CFL), which provides a 30 % Energy saving as compared to conventional fluorescent lamps. This in turn contributes 137 kWh (units) savings per day and 41 511 kWh (units) annually
  • Energy saver for lighting system is installed, resulting in a 12 % of energy saving. This contributes savings of 37 595 kWh (units) per annum
  • Fuel additive for the diesel generator results in a 4 % savings on diesel. This results in savings of 7 770 litres of diesel every year
  • Borehole water is used for the entire facility
  • Treated effluent is used for toilet and garden water requirements
  • The Steam boiler is in the process of being replaced with a hot water generator for the granulation equipment and coating area. This will result in savings of 5 500 litres of diesel per month and 66 000 litres of diesel per annum
  • The above project will result in 250 KL (kilo litres) of water savings per month and 3 000 KL per annum and savings of 300 litres of chemicals per annum
  • A Building Management System (BMS) for Heating, Ventilation and Air Conditioning (HVAC) is to be made operational. This will result in net savings of 15 % electricity which equates to 448 110 kWh units per annum
  • External floodlights are controlled by day/night switches
  • Staff are made aware and are disciplined in the application of energy saving practices which include switching off lights when not in use
  • Heat recovery has been implemented at Block B by controlling the exhaust and supply of air through Air Handling Units
  • Solar street lights are being investigated
  • Rain Water harvesting is being investigated
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