Re-designing the Coffee-maker SIEMENS TC...

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Re-designing the Coffee-makerSIEMENS TC 40105

by Davor Kontic,

Evald Kranjcevic,

Spela Ursej

Introduction

Assuming the average person, older than 16 years, drinks 1 cup of coffee per day in Slovenia: 2.000.000 ‐ 350.000 (younger than 16 years) = 1.650.000 people * 365 days = 0,6 billion coffees per year in Slovenia

more than 400 billion cups of coffee per year around the world (DrogaPortoroz, http://www.droga.si/default.asp?id=201)

Types of coffees common in Slovenia:

‐ filter coffee (as in Germany and USA)

‐ turkish coffee (mainly Turkey, Greece, Bosnia, Montenegro)

‐ expresso coffee (mainly in cafes and bars)

‐ moka coffee (the modern form of coffee)

Drinking coffee is strongly associated with personal habits, social life and national tradition.

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Introduction

Our coffee maker under study is made by Siemens and is of type 1.

Its industrial code is TC 40105.

Siemens produces filter coffee makers of two kinds (http://www.siemens‐hausgeraete.de):

Type I: A filter bracket is attached to the machine skeleton and is swayed sideways when a filter is changed.

Type II: A filter bracket is not attached to the machine skeleton but is stuck upright in the machine when a filter is changed.

A filter coffee‐makerCharacteristic parts of the machine are

(http://www.siemens‐hausgeraete.de):

‐ Compact structural shape with water canister

‐ A filter bracket

‐ Glass pitcher

‐ Electrical parts (cables, electrodes)

‐ Warming parts (heating pipe, heating plate)

‐ Button and light

A coffee maker consists of approximately 30 components, some of which are complex and impossible to further disassemble.

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Measurements of the coffee‐maker

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Packaging

Packaging size (cardboard box):

350 x 220 x 260 mm = 0.496 m2

Cardboard size & weight:

0.496 m2 x (500 g/m2) = 248 g

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Recycling Potential

Short disassembly time

Use of snaps for assembly (only 2 screws used)

No evident hazardous materials

Certain parts are impossible to disassemble, but there exists thepossibility of thermal splitting (warming pipe, consisting of ceramics and aluminium).

Ability to re‐assemble ‐ a potential for re‐use

Recycling Potential

PLASTICS: Recycling of polypropylene (PP) is technically possible (http://www.visionengineer.com/env/pp_recycling.php), but the obstacles are its separation from its own variations and other plastics. Re‐use of old parts to produce new ones represents an encouraging alternative.

METALS: can be recycled and re‐used by melting.

GLASS: can be recycled by melting if small amount of ceramics is included (http://www.gpi.org/Handling.html).

RUBBER: could be recycled and reused (www.itdg.org/docs/technical_ information_service/recycling_rubber.pdf ), but parts installed in coffee maker are low weighted and small.

CERAMICS: could be re‐used after metal removal by melting

Mixed‐material parts: cables could be recycled (seen in “Srebrni loti” firm), other parts are small and low‐weighted.

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Annual Sales & Quantities(for Siemens TC 40105 only)3 sources investigated:

Slovenian statistical office (only quantities of some kitchen appliances per home) – no adequate data available

Contact with inquiry and research firm, named Gtk Gral Iteo ‐ no response

Contact with Siemens AG

10333Annual sales in EU **

31000Total sales in EU *

138Total sales of Siemens TC 40105 in Slovenia

* Total sales in EU is based on assumption that EU has population of 450 mio compared to 2 mio in Slovenia.** Siemens TC 40105 has been on the market for three years – annual EU sales represents approximately 1/3 of total EU sales.

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Annual Sales & Quantities

During our research we have found out that the design used in SiemensTC 40105 is sold under three different brand names:

SIEMENS,

BOSCH, and

GORENJE.

31000Annual sales in EU

93000Total sales in EU

414Total sales of Siemens TC 40105 and other two brand names

For that reason we have tripled our existing sales numbers (see previous page) as follows*:

* Based on assumption that all three brand names have an eaual market share.

Required petroleum


146940273470Total sales in EU

6542327Total sales in Slovenia

1.5820.79Our coffee maker

Total Petroleum used (kg)

kg Petroleum/kg PlasticsPlastics (kg)

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Required energy for coffee‐makerassembly (without packaging)

4602110101534367012666642222Total

5657531882514500060000125554185Mixed

371381246‐‐‐676002046682Rubber

297686992291300030000228787626Glass

5623902187130140320279720139504650Aluminium

3271112418100400001767589Steel

310854591036182042300743007347024490Plastics

Recycled source

Primary source

Recycled source

Primary source

Recycled source

Primary source

Total Energy Requirements (GJ)

Total (annual) Energy Requirements (GJ)

Specific Energy Requirements

(kJ/kg)Total quantity in EU (kg)

Annual quantity in EU (kg)

Material

Packaging resources (paper)

395221.713623064Total sales in EU

131741.71367688Annual sales in EU

0,41.71360.248Single coffee‐maker

total oil used (kg)oil (kg)



0.010.0250.248Single coffee‐maker

total water used (m3)water (m3)



2,510.0610.248Single coffee‐maker

Total electricity used (kWh)Electricity (kWh)




Total trees usedTrees

Total resourcesResource/kg paperPaper (kg)

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Required filter‐paper for operation




total oil used (kg)oil (kg)




total water used (m3)water (m3)




Total electricity used (kWh)Electricity (kWh)




Total trees usedTrees

Total resources per yearResource/kg paper per

yearPaper (kg) per year

*

* Based on assumption that each coffee‐maker uses 1 filter‐paper (2g) per day.

Energy required for operation

* Based on assumption that electric heater of single coffee‐maker operates 0.3 hours per day (in average).


8248622912875763762569750000Total sales in EU


0.89246.482.1750Our coffee maker

Total Electricity Consumption in

EU (GJ)


EU (kWh)

Annual Electricity Consumption

(kWh) *Electric Power

(W)

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Energy Hierarchy

Production

11010 GJ in EU (virginmaterials)

or

4602 GJ in EU (recycledmaterials)

Operation

Electricity usefor operation: 82486 GJ in EU

Electricity usefor makingfilter paper (peryear): 2459 GJ in EU

Electricity usefor makingpackagingpaper: 835 GJ in EU

Electricity consumption is far most important energy related issue.

If coffee makers are made fromrecycled materials instead of virginmaterials, the energy consumption forproduction is reduced more than 50%.

We did not find any data aboutenergy consumption oftransportation, but we assume it to below (we have not taken it into accountin our calculations)

We did not find any data aboutenergy consumption of assembly anddissassembly, but we assume it to below (short time of dissassembly)

General assumptions for re‐design

We assumed that the efficiency of electric heating device could not be significantly improved (mainly because of its simplicity – i.e. conversionof electrical energy into thermal energy).

However, we established that electricity consumption could be reduced by improving thermo‐isolative characteristics of coffee‐maker (thermo jug).

Packaging could not be reduced due to the safety reasons (if we use less paper then product could be easily damaged during transportation).

The size and mass of product could not be significantly reduced otherwise it could easily lose its practicability.

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Coffee‐maker alternatives

ShallowDesign for recyclingMaterial identification

ShallowDesign for recyclingReplace rubber with plastic

ShallowDesign for recyclingNo use of ceramics in glass

ModerateDesign for recyclingRe‐design a skeleton of machine (reducing No. of parts)

RECYCLING

Shallow / moderate

DematerializationReuse of rubber parts (pipes, foots)

ModerateDematerializationReuse of technical parts (thermostats, heating parts)

ModerateDematerializationRedesign cablesREUSE

ModerateReduction of parts numberRedesign of water reservoir (a hole instead of cover)

ModerateReduction of E consumptionUse of warmth keeper (thermo jug)

Shallow/moderate

DematerializationBigger capacities of coffee makers (use in offices)

REDUCTION

DeepProduct changeCoffee automat (service)

DeepProduct changeTurkish or mocca coffee

Deep greenSocial / habits changeAvoid drinking coffeeAVOIDANCE/SUBSTITUTION

Intensity of change

TypeAlternativeIndustrial ecology paradigm

Redesigning the coffee‐maker

To further calculate material and energy savings weredesigned the coffee maker in the following way:

Substitution of glass jug with thermos (additional 141g of plastics needed) in order to keep coffee warm and avoid a need for re‐warming (we assumedelectricity savings of 30%):

Coffee maker with thermos jug

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Substitution of paper filters with permanent metal (additional 4g of metal needed) or fabric filter in order to eliminate paper consumption:

Redesign of power cable ‐ enabling the cable to be separated (detached) from coffee maker and reused (126g of materials savings):

Metal filter Cotton filter

Detachable cable

Recalculated material andenergy consumption

5163119991721400014015146717Total

5657531882514500060000125554185Mixed

371381246‐‐‐676002046682Rubber

297686992291300030000228787626Glass

5623902187130140320279720139504650Aluminum

3986132918100400002139713Steel

366264331221214442300743008658328861Plastics

Recycled source

Primary source

Recycled source

Primary source

Recycled source

Primary source

Total Energy Requirements (GJ)

Total (annual) Energy Requirements (GJ)

Specific Energy Requirements (kJ/kg)Total

quantityin EU (kg)

Annual quantity in EU (kg)

Material

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Energy required for operation


5774016039013534633869750000Total sales in EU


0.62172.557.5750Our coffee maker


EU (GJ)


EU (kWh)

Annual Electricity Consumption

(kWh)Electric Power(W)

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Conclusions

Most of energy is used for operation. Redesign should be focusedprimarily on energy consumption required for heating, since it represents approximately 85% of all required energy in our productLife‐Cycle‐Assessment.

A significant opportunity for energy savings (more than 30%!) andconsequently also for pollution reduction emerges with replacementof a glass juf for a thermo jug.

Conclusions

Further reduction of materials (dematerialization) for product assembly is difficult to achieve – current product is already well designed (the same design is used by three different companies –brand names!)

All of our chosen re‐design steps (thermo jug, metal filter and removable cabling) are already implemented in some other Siemens’s models – however, also at higher product price!

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