The Sport Sandal… - dartmouth.educushman/courses/engs171/Sandal.pdf · 1 Contents Problem...

The Sport Sandal…

LCA of (Re)Tire-d Soles Laura Weyl, Ben Koons, Swetha Sampathgiri, and

Nandan Shetty

ENGS 171

S08

1

Contents

Problem Statement

Manufacturing LCA of Chaco

Tire Waste

Manufacturing LCA of the (Re)-tire-d Sole

Crumb Rubber

Transportation

Lifetime

End Life

Results and Conclusions

Citations

Appendix

2

Problem Statement

The market for sport sandals has greatly increased over recent years, while attention to environmental impact has been ignored. With 189 kTons of virgin rubber used each year, we believe there is potential for redesign that will greatly improve the environmental impact of the sport sandal by using recycled rubber tires.

Manufacturing LCA of Chaco

Chaco sandals are made from four major components, which can be broken down into materials and processes. There is the shoe bed, made up of synthetic rubber and polyurethane, which makes up the majority of each 29 oz. shoe. There is a single strap made of polyester webbing and finally a small plastic buckle. In order to make and assemble each sandal, materials must be extracted and synthesized into rubber and then molded to the shape of the shoe bed. The polyurethane is chemically produced and stamped, which happens in China before being shipped to the US. The polyester webbing is manufactured in France and then shipped to the US for cutting and assembly. In Colorado, the sole is trimmed and the webbing is sewn to the foot bed and woven through the shoe using textile machining and manual assembly.

10%

12%

67%

3%

1%

7%

Rubber Manufacturing Energy Usage (MJ per pair of chacos)

Electricity

Coal

Natural Gas

Distillate

JetFuel

Residual

Rubber manufacturing Energy Usage

Each process, starting with the synthetic rubber manufacturing, was carefully dissected and considered for energy use, emissions, and toxic releases for a variety of categories. The results can be seen in Appendix I. The data has been approximately calculated for a single pair of Chaco sandals men’s size 9 (considered to be average weight and most popular shoe sold) using the Carnegie Mellon University website.

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Rubber manufacturing uses about 18.7 MJ of energy, creates about 0.144 oz. of CO emissions, and releases about 1.54 grams of toxic waste into the land and water streams. Polyurethane manufacturing utilizes 44 MJ of energy, creates about 0.5 oz. of CO emissions, and releases as much as 3.3 grams of toxins into to water and land systems. Polyester manufacturing uses 8 MJ of energy, creates as little as 0.08 oz. of CO emissions, and releases 0.85 grams of toxins per pair of Chaco sandals. Finally, textile machining uses about 2.3 MJ of energy, creates less than 0.06 oz. of CO emissions, and releases 0.35 grams of toxins. Though there are numerous ways to improve the life cycle environmental impact of sandal production, the focus of the remainder of this project will be on eliminating and reducing the embodied energy of sandal production. The embodied energy in manufacturing appears to be more influential than the emissions and toxic releases. It is made up of nearly 50% Natural Gas consumption, followed closely by coal burning, and production of electricity making up the next 25% of the embodied energy in Chaco manufacturing. The total energy usage for a pair of Chaco sandals is 73.3 MJ, 79.4 TJ a year!

Tire Waste

Used tire disposal is a huge problem all over the world. In the US alone there are over 290,000,000 tires disposed of each year. Although they have a high energy and material value most end up in a landfill or are illegally dumped. They then become breeding grounds for mosquitoes and rodents. Although tires are not considered hazardous waste by the EPA they still pose serious environmental risks. They are a high fire hazard when stores together. When burnt they release toxic gas, heavy metals and oil. There is 55,000 gallons of oil run off for every million tires burned.

To reduce the environmental impact of used tires and recapture some of their value there has been a recent increase in the market for post consumer tires. They are used for a variety of applications including: noise barriers, artificial reefs, fuel, Earthship houses, road paving mix, sports surfaces, roofing, solid rubber wheels, shoes and more.

Manufacturing LCA of the (Re)-tire-d Sole

The concept behind the (Re)-tire-d Sole is to utilize existing rubber from recycled vehicle tires rather than using virgin rubber, therefore cutting out the entire rubber manufacturing process from the Life Cycle Analysis of our new shoes. The (Re)-tire-d Sole has three main components, all made from recycled rubber. First, the shoe sole cut or stamped out of recycled tires. Next, the crumb rubber shoe base is added for comfort and durability, and finally, there will be a rubber strap. The three components will all be connected using a shoe adhesive. The overall shoe will weigh about 600 grams when manufacturing and assembly is complete.

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Recycled tires are retrieved and shipped to factory locations from within the United States before being cut, churned, and assembled into (Re)-tire-d Soles. The environmental footprint due to the shipping is addressed in the section devoted to transportation. We would suggest that each manufacturing site employ manual laborers to cut the tires for the shoe soles, therefore employing more American citizens and boosting the local economy. The direct environmental impact of this would be negligible. In order to save money and possibly be more profitable in the long run, machinery could be purchased to automate the stamping of the rubber into the forms of straps and shoe soles. The energy use to stamp a single pair of (Re)-tire-d Soles is 6.9 MJ. The associated CO emissions are about 5.9 grams per pair of shoes, and the total associated toxic releases for land and water are 1.5 grams. Clearly the addition of this automated process increases the overall environmental impact of the (Re)-tire-d Sole significantly.

Energy Use from Rubber Stamping

18%

22%

44%

2%

3%

7%

0%

2%

2%

Elec (MkWh)

Coal

NatGas

LPG

MotGas

Distillate

Kero

Jetfuel

Residual

Rubber Stamping Energy Use

The second major factor in manufacturing the (Re)-tire-d Sole is the adhesive used to connect the strap to the sole and the sole to the crumb rubber shoe base, as well as the adhesive used to hold the crumb rubber in place. The use of adhesives in shoes is very common and difficult to avoid. The energy used to make the adhesive is as high as 1.2 MJ per pair of shoes. The associated CO emissions are about 0.9 grams per pair of shoes, and the total associated toxic releases for land and water are 0.12 grams, see Appendix 2 for more detailed data.

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In summary, assuming that the (Re)-tire-d Sole replaces Chaco sales making 520,000 shoes each year, manufacturing will utilize 4.9 TJ of energy every year, it will create 3,558 kg of CO each year and release 663.2 kg of toxins into the surrounding land and waterways. Though these numbers appear large and of course are not ideal, they are significantly lower than the 79 TJ of energy used to manufacture Chacos each year.

Crumb Rubber

Crumb Rubber consists of shredded tire particles ranging from about 5mm to 1 mm. The most common method for shredding is the crackermill process that tears apart the tire using corrugated steel drums. It takes 1.84 MJ/kg of energy to shred tires with this method, leading to .55 MJ/ pair of sandals totally .285 TJ per year. Other methods, such as granulation and micro-milling, are also used and require similar infrastructure and energy. Looking more closely at the energy breakdown it turns out that only about 5% of the total energy in used for the shredding process and the rest is used for transportation. To reduce the transportation component it makes sense to decentralize the shredding process with more smaller, and potentially portable, shredders. It is safe to assume that decentralization could reduce the transportation impacts by up to 25% and would potentially increase the shredding energy by a factor of two due to the smaller size. This results in an energy use of .65 MJ/kg or .102 TJ/year, a reduction by almost a factor of 3.

Packaging

Chaco packaging uses close to 100% recycled content, broken down into two different types: recycled corrugated cardboard boxes with tissue paper, as well as biodegradable corn polymer bags. The greatest environmental impact occurs with the cardboard box packaging method.

Corrugated fiberboard consists of one inner layer of pleated paperboard sandwiched between and glued with starched based adhesives to two flat pieces of kraft paper with a typical density of approximately 127 g/m2. Each box also contains 1ft2 of wrapping tissue paper. Paper production is an energy intensive process, and cardboard boxes are not environmentally friendly. Were Chaco to package only with cardboard boxes, packaging energy use would sum to 11.05 TJ/yr, toxic releases 2.88 MT/yr, and emissions 781.2MT/yr. This amount could be reduced by preferentially packaging with the biodegradable corn polymer bag method.

Chaco polymer bags are produced from Polylactic Acid (PLA) generated from cornstarch. PLA is both made from a renewable resource and is biodegradable, two fundamentals of sustainability. However, plant-based plastics are also associated with environmental issues. For example, the biological breakdown of plastics releases carbon dioxide and methane. In addition, creating plastic from plants has an enormous energy requirement. Fossil fuel energy also goes into producing pesticides, herbicides, and fertilizer for corn. While having less of an eco-footprint than cardboard boxes, in many

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ways PLA bags have a much bigger environmental impact than conventional polyethylene plastic bags. While Chaco PLA plastic packaging would consume 1.74 TJ/yr, release .133MT/yr of toxic releases, and emit 243.3 MT/yr of greenhouse gases, polyethylene bags would total .23TJ/yr, .019MT/yr, and 17.8 MT/yr, respectively.

Given this disparity, one might question why PLA is to be preferred over polyethylene. One major consideration is that the major producer of PLA, Natureworks LLC, offsets all non-renewable energy with wind power renewable energy certificates, making them the 19th largest carbon offsetter in the country. Furthermore, the biodegradable plastic industry is very young compared to petro-chemical manufacturing. With time, energy efficiency will improve, and Natureworks has improved the energy efficiency of their PLA production every year, resulting in significant reductions in pollutants and energy consumed. Finally, PLA is currently produced from corn, an over subsidized agribusiness that is too energy intensive and uses more nitrogen fertilizer, herbicides, and insecticides than any other US crop. PLA could instead be produced from cellulosic biomass, grasses, wheats, beats, and potatoes, which would require less energy. The corn market surplus is the problem. PLA is not, and polyethylene, a non-renewable plastic manufactured from petroleum should not be favored.

The LCA of the (Re)Tire-d Sole should incorporate PLA polymer bags to be shipped to customers. However, less than 1% of Chaco sales are direct; almost all are retail. For retail sales, perhaps the bag could be avoided entirely. The (Re)Tire-d Sole sandals could be tied together with a string and shipped to the retailer in large bulk cardboard boxes. Despite the environmental gains with this approach, a customer might alternatively prefer that their new sandals arrive in a bag. The total environmental impact from packaging the (Re)Tire-d Sole using these two options is listed in the following table.

Large Boxes with PLA bags

Only Large Boxes

Energy 3.09 TJ/yr 1.35 TJ/yr

Toxic Releases .48 MT/yr .35 MT/yr

Emissions 338.57 MT/yr 95.27 MT/yr

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Transportation

Transportation of goods is a high energy consumption sector. With increasing globalization, goods are transported across the world by sea or air freight. The footwear industry in the US imported over 2.2billion pairs in the year 2007 mainly from China.

Chaco

Chaco ships all if its raw materials from China. Shipping is a relatively environment-friendly mode of transportation in terms of tons transported per trip or tons per gallon of fuel. They do not use air freight to transport any material.

The materials are assembled in Colorado and transported to 1799 dealers all over the US. All products are moved only using truck transport. Truck transport uses distillate, gasoline or diesel for fuel implying that the emissions are mainly CO2 and NOx.

Assumptions:

For our calculations, we have assumed an average distance of 1342miles which is an average transportation distance for retail stores. Shipping distance is considered from Shanghai to LA and fuel consumption calculated according to nautical miles. The average capacity of a cargo freighter is 9000 TEU (twenty-foot equivalent units) each of which can carry about 21.6 tons. All of the raw material from China was assumed to be transported in one trip and a fraction of the weight of the ships capacity was considered. Similarly, a fraction of the 18-wheeler truck transportation was considered which has an average capacity of 60tons.

Based on these assumptions, the energy for shipping from China was about 5600MJ/yr. Transportation within the US consumes more energy of over 309,500MJ/yr.

Local Manufacturing:

Energy utilization by transportation can be decreased significantly if manufacturing units are located close to the source of raw materials. Also, decentralized manufacturing at multiple manufacturing units can reduce transportation from manufacturing plant to warehouse and then to retail stores and instead can be shipped directly to the retail stores. There are over 3000 landfills in the US

Assumptions:

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There are over 3000 landfills in the US and we assumed 10% of them would have tires being dumped in them. This gives us 300 manufacturing units across the US. If we consider a 100km radius these 300 would cover the area of USA. We then considered that each of these units sold to one retail outlet at an average distance of 50km.

According to these assumptions, the total transportation energy drastically reduces to 3000MJ/yr which is about 1% of the energy currently being consumed. See appendix III for a detailed analysis.

The impact of transportation can be reduced by locating manufacturing units close to the source of raw material. Increasing fuel efficiency of these trucks is also important. The impact of transportation can also be reduced by reducing the number of trips and increasing the number of sandals shipped on each trip. Also, using renewable energy or bio-fuels can reduce our dependence on fossil fuels.

Lifetime

Chaco Sandals have zero energy and resource use. They do, however have very slight material emission during use. Small amounts of the outer sole wear off and can potentially contaminate the environment. There have been several studies into the potential toxic effects of this sole residue from commercially available shoes. It turns out that tire rubber is much less toxic than standard footwear rubber and is much more abrasion resistant. This is primarily due to the fact that tires loose up to 20% of their mass while in use on the road, and therefore must be made from a fairly inert material. Also, the wear and tear of walking on a tire sole is significantly less than the wear the tire is designed for. The life time of a Chaco is about 2-3 years, although this varies considerably as they are generally not an individual’s primary footwear.

End Life

Although it is possible to resole Chaco sandals, the majority of them end up in the landfill. The materials are fairly inert so the main environmental end-of-life impacts are due to the transportation involved in disposal. The resoling involves similar transportation modes as the disposal so for the analysis it is safe to assume that all shoes, or each resoling, have the same transport related impact. Transport of disposed Chaco’s cost $80/ton which creates $16.7 TJ/ Million S, resulting in 1.7 MJ/pair. Assuming steady state in the sandal business, 520,000 Chaco’s are being disposed of annually, using .88 TJ/year.

Results and Conclusions

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The sport sandal is a rapidly growing market that targets an active, and environmentally conscious user group and despite manufacturers awareness of environmental impact, there is room for improvement. Over 189 kTons of virgin rubber are used to make sport sandals each year, while 244,890 tons of rubber is sent to landfills in the form of vehicle tires each year. This proposal outlines the manufacturing redesign of the sport sandal to maintain comfort and durability while decreasing the environmental footprint of each and every shoe. The (Re)Tire-d Sole uses 100% recycled rubber and the only virgin material used in any part of the shoes is the adhesive. Transportation is kept to a minimum by having multiple manufacturing sites around the country and utilizing a vehicle that creates the crumb rubber while transporting the tires to factories. Packaging costs are also minimized by eliminating the individual box used for each pair of shoes with a simple tie connection.

Overall we find that if the (Re)Tire-d Sole were to replace the 520,000 pairs of shoes made by Chaco each year, 79 TJ of energy would be conserved and CO emissions would decrease by 3,251 Tons. The many assumptions made to calculate these results were “worst case scenarios,” therefore in reality the savings may be even greater than estimated. Chaco is the leader in environmental awareness among sport sandals today, therefore decreasing the number of other sport sandals manufactured would only increase the above stated savings. We also assumed every shoe to be the size of a Men’s size 9, which is unrealistic; many of the shoes would use less material and weigh less during transportation. We feel confident proposing the (Re)Tire-d Sole design for the new and improved sport sandal for its large environmental savings and positive social impact.

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Citations

http://www.epa.gov/epaoswer/non-hw/muncpl/tires/basic.htm

http://thenumbersguru.com/2006/07/26/tires-in-the-united-states/

http://www.esupplystore.com/Brown-Corrugated-Boxes_c_67.html

http://en.wikiversity.org/wiki/DFE2008_Grocery_Bags

http://www.natureworksllc.com/our-values-and-views/life-cycle-assessment/~/media/Our%20Values%20and%20Views/LifeCycleAssesment/Basic_LCA/NTR_CompleteLCA_1102%20pdf.aspx

Shades of Green. Popular Science, September 2007

How Green are Green Plastics? Gerngross, Tillman and Steven Slater. Scientific American, August 2000

http://www.scribd.com/doc/518871/Corrugated-Fiber-Board-Boxes

http://www.articlesalley.com/article.detail.php/18210/160/Fashion-Style/Shopping-and-Product-Reviews/21/Choosing_Footwear_-_Why_Choose_Sandals

Charting the Course: Marine fuel efficiency and Emissions Conference, 2005

http://www.the-infoshop.com/study/pf36793-footwear.html

http://www.fdra.org/Statistic%20Charts/stats.html

http://www.sginews.com/sginews/gifs/SGI_rugfw_2003.pdf

http://www.researchwikis.com/Footwear_Market_Research

http://www.apparelandfootwear.org/Statistics.asp

http://en.wikipedia.org/wiki/Containerization

http://en.wikipedia.org/wiki/Container_ship

http://www.epa.gov/garbage/tires/basic.htm

http://www.rma.org/scrap_tires/scrap_tire_markets/scrap_tire_characteristics/#anchor135840

http://www.newsfactor.com/perl/story/16721.html

http://p2library.nfesc.navy.mil/P2_Opportunity_Handbook/7_I_A_10.html

http://www.bitre.gov.au/publications/33/Files/WP004.pdf

http://www.epa.gov/epaoswer/non-hw/muncpl/landfill/tab_1.pdf

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Appendix

Appendix I- Rubber Manufacturing

10%

12%

67%

3%

1%

7%

Rubber Manufacturing Energy Usage (MJ per pair of chacos)

Electricity

Coal

Natural Gas

Distillate

JetFuel

Residual

Energy Total (TJ) Elec (MkWhCoal NatGasDistillatJetFuel ResidualTotal 26.60 0.72 3.25 17.50 0.75 0.17 1.86Synthetic Rubber Manufacturing 14.20 0.32 0.00 11.40 0.03 0.00 1.56Power generation and Supply 3.57 0.00 2.83 0.63 0.00 0.00 0.11Petroleum Refineries 1.77 0.03 0.00 0.86 0.01 0.17 0.06Pertochemical Manufacturing 1.49 0.03 0.00 1.35 0.00 0.00 0.01Other chemical Manufacturing 1.08 0.07 0.17 0.77 0.00 0.00 0.01

MJ/pairTotal 18.69 1.81 2.28 12.29 0.53 0.12 1.31Synthetic Rubber Manufacturing 9.98 0.80 0.00 8.01 0.02 0.00 1.10Power generation and Supply 2.51 0.00 1.99 0.44 0.00 0.00 0.08Petroleum Refineries 1.24 0.08 0.00 0.60 0.00 0.12 0.04Pertochemical Manufacturing 1.05 0.08 0.00 0.95 0.00 0.00 0.00Other chemical Manufacturing 0.76 0.17 0.12 0.54 0.00 0.00 0.01

13

20%

46%

16%

16%

0% 2%

Rubber Manufacturing Emissions (ounces/pair of chacos)

SO2

CO

NOx

VOC

Lead

PM10

Emissions SO2 (mt) CO Nox VOC Lead PM10Total 2.500 5.830 1.970 2.070 0.000 0.317Power generation and Supply 1.630 0.081 0.739 0.007 0.000 0.035Pertochemical Manufacturing 0.282 0.090 0.212 0.671 0.000 0.016Petroleum Refineries 0.155 0.090 0.035 0.124 0.000 0.016Oil and Gas extraction 0.111 0.189 0.083 0.127 0.000 0.004Other chemical Manufacturing 0.065 0.007 0.004 0.004 0.000 0.004

Ounces/pairTotal 0.062 0.144 0.049 0.051 0.000 0.008Power generation and Supply 0.040 0.002 0.018 0.000 0.000 0.001Pertochemical Manufacturing 0.007 0.002 0.005 0.017 0.000 0.000Petroleum Refineries 0.004 0.002 0.001 0.003 0.000 0.000Oil and Gas extraction 0.003 0.005 0.002 0.003 0.000 0.000Other chemical Manufacturing 0.002 0.000 0.000 0.000 0.000 0.000

14

10%13%

24%

2%6%5%

37%

3%

Rubber Manufacturing Toxic Releases (grams per pair of chacos)

Non-Point

Point

Total Air

Water

Land

Underground

Total

POTW

ToxinsNon-Point (kg)

Point TotAir Water Land U'ground Total POTW

Total 612.00 809.00 1420.00 114.00 362.00 297.00 2190.00 164.00Synthetic Rubber Manufacturing 541.00 618.00 1160.00 43.40 2.64 113.00 1320.00 10.60Petrochemical Manufacturing 23.20 32.40 55.60 23.00 1.31 78.70 159.00 64.20Other chemical Manufacturing 19.30 32.80 52.10 19.50 1.13 55.60 128.00 44.40Petroleum Refineries 8.07 12.10 20.20 7.64 0.41 0.96 29.20 1.52Plastid and Resin Manufacturing 5.16 11.20 16.30 1.22 0.07 5.96 23.60 9.71

Grams/pair

Total 0.430 0.568 0.998 0.080 0.254 0.209 1.539 0.115Synthetic Rubber Manufacturing 0.380 0.434 0.815 0.030 0.002 0.079 0.927 0.007Petrochemical Manufacturing 0.016 0.023 0.039 0.016 0.001 0.055 0.112 0.045Other chemical Manufacturing 0.014 0.023 0.037 0.014 0.001 0.039 0.090 0.031Petroleum Refineries 0.006 0.009 0.014 0.005 0.000 0.001 0.021 0.001Plastid and Resin Manufacturing 0.004 0.008 0.011 0.001 0.000 0.004 0.017 0.007

15

13%

17%

55%

6%

2% 4%

0%

1%

2%

Polyurethane Manufacturing Energy Usage (MJ per pair of Chacos)

ElectricityCoalNatural GasLPGMotGasDistillateKeroJetfuelResidual

Energy

TJ Total Elec (MkWhCoal NatGas LPG MotGas DistillateKero Jetfuel Residual

Total 22.700 0.899 4.270 13.800 1.640 0.412 0.935 0.000 0.207 0.416

Plastic Material and Resin Manuf 7.880 0.431 0.507 6.360 0.367 0.093 0.028 0.000 0.000 0.049

Power Generation and Supply 4.090 0.000 3.240 0.725 0.000 0.000 0.000 0.000 0.000 0.124

Petroleum Refineries 2.000 0.037 0.000 0.967 0.903 0.007 0.006 0.000 0.000 0.071

Petrochemical Manufacturing 1.730 0.037 0.000 1.560 0.097 0.018 0.005 0.000 0.000 0.006

Other Chemical Manufacturing 1.610 0.101 0.254 1.140 0.071 0.013 0.003 0.000 0.000 0.013

MJ/pair

Total 44.038 6.279 8.284 26.772 3.182 0.799 1.814 0.000 0.402 0.807


Power Generation and Supply 7.935 0.000 6.286 1.407 0.000 0.000 0.000 0.000 0.000 0.241




16%

41%13%

27%

0% 3%

Polyerethane Manufacturing Emissions (ounces per pair of chacos)

SO2

CO

NOx

VOC

Lead

PM10

16

Emissions Metric Tons SO2 CO Nox VOC Lead PM10

Total 2.94 7.56 2.45 5.01 0 0.468

Power Generation and Supply 1.87 0.092 0.845 0.008 0 0.04

Petrochemical Manufacturing 0.327 0.105 0.246 0.777 0 0.018

Petroleum Refineries 0.175 0.101 0.039 0.14 0 0.018

Oil and Gas Extraction 0.142 0.241 0.106 0.162 0 0.005

Other Chemical Manufacturing 0.067 0.007 0.005 0.004 0 0.004

Ounces/pair

Total 0.197 0.507 0.164 0.336 0.000 0.031

Power Generation and Supply 0.125 0.006 0.057 0.001 0.000 0.003

Petrochemical Manufacturing 0.022 0.007 0.016 0.052 0.000 0.001

Petroleum Refineries 0.012 0.007 0.003 0.009 0.000 0.001

Oil and Gas Extraction 0.010 0.016 0.007 0.011 0.000 0.000

Other Chemical Manufacturing 0.004 0.000 0.000 0.000 0.000 0.000

3%

7%11% 2%

7%

5%24%

6%

2%

33%

Polyurethane Manufacturing Toxic Emissions (grams per pair of Chacos)

Non-Point Air (kg)

Point Air

Tot Air Releases

Water Releases

Land Releases

U'ground Releases

Total Releases

POTW Transfers

Offsite Transfers

Total Rel/Trans

ToxinsNon-Point Air (kg)

Point AirTot Air Releases

Water Releases

Land Releases

U'ground Releases

Total Releases

POTW Transfers

Offsite Transfers

Total Rel/Trans

Total 215 517 732 118 455 377 1680 422 146 2250

Plastic Material and Resin Manuf 127 275 402 30 1.62 146 580 239 35.2 853

Other Chemical Manufacturing 28.6 48.7 77.4 29 1.67 82.6 191 65.9 24.5 281

Petrochemical Manufacturing 26.9 37.5 64.4 26.6 1.52 91.1 184 74.4 28.2 286


Other basic Inorganic Chemical M 5.03 17.1 22.1 6.93 13.9 19.9 62.8 10.9 8.26 82

Grams/Pair

Total 0.417 1.003 1.420 0.229 0.883 0.731 3.259 0.819 0.283 4.365





Other basic Inorganic Chemical M 0.010 0.033 0.043 0.013 0.027 0.039 0.122 0.021 0.016 0.159

17

14%

23%

49%

4%1%

3% 0%1%

5%

Polyester Manufacturing Energy Usage (MJ per pair of Chacos)

ElectricCoalNatGasLPGMotGasDistillateKeroJetfuelResidual

Energy TJ Total ElectricCoal NatGas LPG MotGas Distillate Kero Jetfuel Residual

Total 22.90 0.96 5.74 12.30 1.06 0.38 0.87 0.00 0.18 1.36

Noncellulosic organic fiber manufa 10.70 0.57 1.80 6.68 0.41 0.11 0.04 0.00 0.00 1.05

Power generation and supply 4.26 0.00 3.37 0.75 0.00 0.00 0.00 0.00 0.00 0.13

Other basic organic chemical manu 1.71 0.11 0.27 1.22 0.08 0.01 0.00 0.00 0.00 0.01

Petroleum refineries 0.75 0.01 0.00 0.36 0.34 0.00 0.00 0.00 0.00 0.03

Plastics material and resin manufa 0.68 0.04 0.04 0.55 0.03 0.01 0.00 0.00 0.00 0.00

MJ/pair

Total 8.04 1.21 2.02 4.32 0.37 0.13 0.31 0.00 0.06 0.48


Power generation and supply 1.50 0.00 1.18 0.26 0.00 0.00 0.00 0.00 0.00 0.05




18

19%

49%

16%

14%

0% 2%

Polyester Manufacturing Emissions (ounces per pair of Chacos)

SO2

CO

NOx

VOC

Lead

Emissions SO2 CO NOx VOC Lead PM10

Total 2.48 6.42 2.06 1.84 0 0.326

Power generation and supply 1.95 0.096 0.88 0.009 0 0.041

Petrochemical manufacturing 0.104 0.033 0.078 0.246 0 0.006

Petroleum refineries 0.066 0.038 0.015 0.053 0 0.007

Oil and gas extraction 0.062 0.106 0.046 0.071 0 0.002

Other basic inorganic chemical ma 0.036 0.004 0.002 0.002 0 0.002

Ounces/pair

Total 0.03073 0.08 0.02552 0.0228 0 0.004


Petrochemical manufacturing 0.00129 4E-04 0.00097 0.00305 0 7E-05

Petroleum refineries 0.00082 5E-04 0.00019 0.00066 0 9E-05

Oil and gas extraction 0.00077 0.001 0.00057 0.00088 0 2E-05

Other basic inorganic chemical ma 0.00045 5E-05 2.5E-05 2.5E-05 0 2E-05

1% 4% 6% 2%

4%

18%

30%

2%

1%

32%

Polyester Manufacturing Toxic Releases (grams per pair of Chacos)

Non-Point Air (kg)Point AirTot Air ReleasesWater ReleasesLand ReleasesU'ground ReleasesTotal ReleasesPOTW TransfersOffsite TransfersTotal Rel/Trans

19

ToxinsNon-Point Air (kg)

Point Air

Tot Air Releases

Water Releases

Land Releases

U'ground Releases

Total Releases

POTW Transfers

Offsite Transfers

Total Rel/Trans

Total 103.0 360.0 462.0 128.0 313.0 1510.0 2420.0 151.0 84.4 2650.0




Petrochemical manufacturing 8.5 11.9 20.4 8.4 0.5 28.9 58.2 23.6 8.9 90.7


Grams/pair

Total 0.036 0.126 0.162 0.045 0.110 0.530 0.850 0.053 0.030 0.931




Petrochemical manufacturing 0.003 0.004 0.007 0.003 0.000 0.010 0.020 0.008 0.003 0.032


Appendix II: Manufacturing LCA of the (Re)‐tire‐d Sole

Rubber Stamping Energy Use:

Energy Use from Rubber Stamping

18%

22%

44%

2%

3%

7%

0%

2%

2%

Elec (MkWh)

Coal

NatGas

LPG

MotGas

Distillate

Kero

Jetfuel

Residual

MJ/pair Total Elec (MkWh) Coal NatGas LPG MotGas Distillate Kero Jetfuel Residual

Total for all sectors 6.948 1.451686047 1.7563 3.4845 0.1468 0.23253 0.561313 0 0.1208 0.19249

Power generation and supply 1.974 0 1.5666 0.34985 0 0 0 0 0 0.059714

Adhesive manufacturing 1.581 0.280726744 0.0745 1.34884 0.0035 0.01124 0.009133 0 0 0.051284

Other basic inorganic chemical m 1.012 0.422354651 0 0.76575 0.0281 0.05901 0.017563 0 0 0.011943

Petroleum refineries 0.275 0.00252907 0 0.00562 0.0007 0.04004 0.228319 0 0 0

Other basic organic chemical man 0.105 0.022761628 0.0267 0.05409 0.0007 0.0007 0.000703 0 0 0.014753

20

Rubber Stamping Emissions:

Rubber Stamping Toxic Releases:

grams/pair SO2 CO Nox VOC Lead PM10

Total 1.36289 5.90818797 1.166182 0.723595 0.00281 0.44048

Adhesive manufacturing 0.90625 0.04496124 0.408164 0.0042151 0 0.018968

Power generation and supply 0.14331 1.21535852 0.112403 0.0681444 0.000703 0.10046

Other basic inorganic chemical m 0.07095 0.00210756 0 0.0035126 0 0.007728

Petroleum refineries 0.0562 0.3119186 0 0.0028101 0 0.01405

Petrochemical manufacturing 0.04988 0 0.011943 0.0112403 0 0.004918

Emissions from Rubber Stamping

14%

61%

12%

8%

0%

5%

SO2

CO

Nox

VOC

Lead

PM10

21

Toxic Releases from Rubber Stamping

1%

3%

4%

1%

22%

1%

28%1%

6%

33%

Non-Point Air (kg)

Point Air

Tot Air Releases

Water Releases

Land Releases

U'ground Releases

Total Releases

POTW Transfers

Offsite Transfers

Total Rel/Trans

Adhesive Manufacturing Energy Use:

Grams/Pair

Non-Point Air (kg)


Water Releases

Land Releases

U'ground Releases

Total Releases

POTW Transfers

Offsite Transfers

Total Rel/Trans

Total for all sectors 0.037234 0.120131 0.157364 0.062384 0.92733 0.02585 1.173207 0.05311 0.239559 1.468266

Adhesive manufacturing 0.015947 0.026625 0.042573 0.00044 7.5E-05 0 0.043064 0.02311 0.022621 0.088517

Synthetic rubber manufacturing 0.00347 0.003239 0.006702 0.043697 0.02908 0.00047 0.080087 0.00115 0.147529 0.228319

Other basic organic chemical man0.002585 0.000557 0.003147 0.000617 0.00941 0 0.013207 4.2E-06 0.00104 0.014261

Plastics material and resin manuf 0.001714 0.005353 0.007095 3.09E-05 0.00062 0 0.007728 0 0.001553 0.009273

Other basic inorganic chemical m 0.000836 0.001419 0.002255 0.000843 4.8E-05 0.00241 0.005557 0.00192 0.000717 0.008219

22

Energy Use in Shoe Adhesive Manufacturing and Use

13%

19%

48%

5%

3%

6%

0%

1%

5%

Elec (MkWh)

Coal

NatGas

LPG

MotGas

Distillate

Kero

Jetfuel

Residual

Adhesive Manufacturing and Use Emissions:

MJ/pair Total Elec (MkWh) Coal NatGas LPG MotGas Distillate Kero Jetfuel Residual

Total for all sectors 1.3432 0.1977264 0.272 0.6992 0.0801 0.0441 0.09476 0 0.0165 0.07498

Power generation and supply 0.2714 0 0.215 0.04812 0 0 0 0 0 0.008188

Adhesive manufacturing 0.2622 0.043056 0 0.18216 0.0107 0.0143 0.001656 0 0 0.040664

Other basic inorganic chemical 0.1049 0.0337824 0 0.08823 0.0052 0.0009 0.000276 0 0 0.000276

Petroleum refineries 0.0915 0.0059616 0 0.04434 0.0414 0.0003 0.000276 0 0 0.003312

Other basic organic chemical m 0.0811 0.018216 0.013 0.05759 0.0036 0.0006 0.000184 0 0 0.000644

23

Total Emissions of Shoe Adhesive Manufacturing and Use

29%

41%

18%

9%

0%

3%

SO2

CO

Nox

VOC

Lead

PM10

Adhesive Manufacturing and Use Toxic Releases:

Toxic Releases in Shoe Adhesive Manufacturing and Use

3%

7%

10%

1%

12%

3%26%3%

2%

33%

Non-Point Air (kg)

Point Air

Tot Air Releases

Water Releases

Land Releases

U'ground Releases

Total Releases

POTW Transfers

Offsite Transfers

Total Rel/Trans

grams/pair SO2 CO Nox VOC Lead PM10

Total 0.6523 0.920015477 0.394 0.1932 0 0.0659

Adhesive manufacturing 0.4683 0.128802167 0.216 0.01794 0 0.0326


Other basic inorganic chemical 0.0095 0.001012017 6E-04 0.00055 0 0.0006

Petroleum refineries 0.008 0.004692079 0.002 0.00644 0 0.0008

Petrochemical manufacturing 0.007 0.002208037 0.005 0.01665 0 0.0004

24

Appendix III: Transportation

0.412

0.001 0.000

0.0120.000 0.000

0.000

Chacos Shipping Emissions in MT/yr

Carbon dioxide

Carbon monoxide

Methane (CH4)

Nitrogen oxides (NOx)

Particulates (PM10)

Sulfur oxides (SOx)

VOC

1928.56

3.07 0.0312.850.05 0.22

0.420.63

Chacos Truck Emissions in MT/yr

Carbon dioxide

Carbon monoxide

Methane (CH4)


Particulates (PM10)

Sulfur oxides (SOx)

VOC

Grams/Pair

Non-Point Air (kg)


Water Releases

Land Releases

U'ground Releases

Total Releases

POTW Transfers

Offsite Transfers

Total Rel/Trans

Total for all sectors 0.01104 0.026956 0.038 0.005216 0.046368 0.012788 0.10212 0.011684 0.00887 0.12328

Adhesive manufacturing 0.003873 0.006955 0.01086 3.9E-05 4.38E-05 0 0.010948 0.000795 0.00139 0.013064

Synthetic rubber manufacturing 0.001481 0.001684 0.00316 0.000119 7.27E-06 0.000308 0.003597 2.91E-05 5.5E-05 0.00368

Other basic organic chemical m 0.001444 0.002456 0.0039 0.001463 8.43E-05 0.004158 0.009568 0.003321 0.00123 0.014168

Plastics material and resin man 0.000871 0.001886 0.00276 0.000206 1.11E-05 0.001003 0.003984 0.001638 0.00024 0.00586

Other basic inorganic chemical 0.00071 0.00241 0.00313 0.000975 0.001969 0.002806 0.008887 0.001536 0.00117 0.011592

25

0.206

0.0010.006

China Imports Shipping Emissions in MT/yr

Carbon dioxide

Carbon monoxide

Methane (CH4)


Particulates (PM10)

Sulfur oxides (SOx)

VOC

964.28

1.530.026.430.02 0.11

0.21

0.32

China Imports Truck EmissionsMT/yr

Carbon dioxide

Carbon monoxide

Methane (CH4)


Nitrous oxide (N2O)

Particulates (PM10)

Sulfur oxides (SOx)

VOC

26

563.16

0.900.013.75 0.01

0.060.12

0.19

Local Emissions in MT/yr

Carbon dioxide

Carbon monoxide

Methane (CH4)


Nitrous oxide (N2O)

Particulates (PM10)

Sulfur oxides (SOx)

VOC

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