Greenfactory : Approach to Environment : CSR Activities : TOTO GLOBAL SITE

The TOTO Group is striving to reduce CO₂ emissions in the manufacturing industry by promoting environment-friendly "green factories". As a model factory, the Shin-nishi Building in the Shiga Plant was constructed in 2012 which introduced the latest energy-saving technologies with superior environmental performance. This effort was highly regarded and was awarded the "Minister of Economy, Trade and Industry Award for Excellence" in FY2013, the grand prize for energy conservation, by the Energy Conservation Case Studies Department. (Winning theme: Model factory project introducing state-of-the-art energy conservation technologies)

Introduction of state-of-the-art energy conservation technologies

High efficiency kiln
New energy-saving air conditioning equipment
High heat insulation (roof, exterior walls, layout)
Individual identification bar code management Plant-wide
energy-saving effect

High efficiency kiln

Exhaust heat recovery Reheating Re-use Re-use of waste heat for the drying chamber

Introduction of a high efficiency, self-regenerating fiber kiln which recovers waste heat, since the kiln consumes the most energy during the manufacturing process of sanitary ware. By recovering waste heat during product cooling, reusing it as combustion air after re-heating, then reusing the waste heat for the chamber, about 71% energy savings is achieved compared to a conventional brick-type firing kiln.

New energy-saving air conditioning equipment

Temperature and humidity meter (for temperature control)

Custom-built energy-saving room air conditioning equipment.

Introduction of a state-of-the-art, high energy-saving performance air conditioning equipment in the molding room where there is a need to keep the temperature and humidity constant throughout the year.
There is increased energy and power savings compared to conventional methods by recovering waste heat from cooling and using it for heating, and by individually controlling the air conditioning to match the load conditions.

High heat insulation (roof, exterior walls, layout)

Load is reduced by combining with the Outer wall - Room - Walkway - Molding Room

Adoption of high thermal insulation materials on the roof and outer walls.
The performance of the air conditioning equipment is also maximized by considering layouts, such as placing the area requiring heavy use of air conditioning in the center of the building where it is less susceptible to the influence of outside air.

Individual identification bar code management

Improved productivity, such as the reduction of stock and inventory task load

Introduction of an individual identification bar code management system (which uses a bar code that can withstand high temperatures of up to 1200℃) in the production line. Improved productivity, such as the reduction of stock and inventory task load, is achieved by managing product information in each process for up to 475 items in real time Using this method together with paperless technology, the amount of energy previously required is significantly reduced.

Plant-wide energy-saving effect

43% reduction of CO2 emissions, exceeding the original target of 30%

Other environmentally-friendly facilities

Solar power

Installation of 50kW solar power panels on the roof.

Energy saving Low-e glass

This glass is used in all windows of the plant. The summer air-conditioning load is reduced by cutting the solar heat by 60%.

High-efficiency lighting and motion sensors

Energy-saving performance is improved by using high-efficiency Hf and LED lighting, as well as motion sensors.

Sanitary ware scrap recycling

Sanitary ware waste materials (ceramic scraps) produced by the manufacturing process are pulverized and reused as road paving material for the plant site. This contributes to the promotion of zero waste.

Hydrotect coat (outer wall)

The outer walls are painted with photocatalyst coating that naturally breaks down dirt. This coating also removes air pollutants.

Energy Management System

Electricity, gas, air, and water usage in each plant is measured and managed for each process. Environmental improvement activities are also leveraged by introducing the BEAMS* energy management system to quantify efficiency.
*BEAMS (Building Environment and Energy Advanced Management System)