DTC51632 DTC FUSION N2 25 PageTurn - Flipbook - Page 25
The Hidden Majority of Emissions
When manufacturers set net zero
goals, they often focus on the
emissions they can see and control:
energy usage, heating, and on-site
processes. These are Scope 1 and
Scope 2 emissions. But there’s a
much larger problem lurking in the
shadows.
Scope 3
Accounts for the indirect emissions
created across the entire value chain,
from the mining of raw materials to
end-of-life product disposal. This
encompasses supplier manufacturing
processes, transportation, product
use, and waste management. For
many sectors, Scope 3 emissions
make up as much as 80 percent of
total carbon output.
Tracking Scope 3 is inherently
complex, requiring collaboration with
suppliers, transport providers, and
even customers. Without tackling
it, any sustainability claim remains
fundamentally incomplete. Yet
the statistics reveal a concerning
gap: 90% of manufacturers lack
comprehensive Scope 3 tracking
systems, with 60% citing supply chain
data as their biggest sustainability
challenge.
The Composite Waste Conundrum
This tracking challenge becomes
particularly acute when dealing with
composite materials: one of modern
manufacturing’s most problematic
waste streams. Composites are
prized across aerospace, marine,
automotive, and sporting industries
for their strength-to-weight ratio,
corrosion resistance, and design
flexibility. These same properties
make them extraordinarily difficult
to recycle.
Consider the aerospace sector: a
single commercial aircraft contains
approximately 20% composite
materials by weight. When these
aircraft reach end-of-life after 20-30
years of service, those composite
components (primarily carbon fibre
reinforced plastics) become virtually
permanent waste. The fibres and
resins are so tightly bonded that they
cannot simply be melted down like
metals or reformed like traditional
plastics.
The wind energy industry faces a
similar challenge. As first-generation
wind turbines installed in the 1990s
reach retirement, their massive
composite blades are ending up in
landfills. A single turbine blade can
be over 100 meters long and weigh 15
tons, with most of that weight being
non-recyclable composite material.
Boeing estimates that by 2030,
approximately 6,000 commercial
aircraft will be retired globally.
Without viable recycling solutions,
the composite components from
these aircraft represent a mounting
waste crisis that directly undermines
Scope 3 emission calculations.
collaboration between manufacturers
who have traditionally viewed
recycling as someone else’s problem.
Practical Steps Forward
Manufacturers serious about
addressing their full carbon footprint
can begin with these concrete
actions:
Immediate steps:
• Map your complete Scope 3
footprint, including end-of-life
disposal
• Engage suppliers with specific
emissions data requirements
• Conduct comprehensive audits of
current waste streams
Strategic initiatives:
• Explore closed-loop material
sourcing partnerships
• Join industry recycling consortia
and pilot programs
• Integrate recyclability
requirements into product design
specifications
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Signs of Innovation
Despite these challenges, promising
developments are emerging
across the recycling landscape.
Chemical recycling processes are
being developed to break down
resins and recover fibres, though
energy requirements remain high.
Companies like Carbon Conversions
and ELG Carbon Fibre are pioneering
mechanical processes that can retain
fibre integrity at 90% of virgin quality.
Some manufacturers are also
embracing design for disassembly
approaches. Airbus has begun
incorporating removable joints and
separable materials in newer aircraft
designs. At the same time, BMW’s
i3 electric vehicle was specifically
engineered to allow carbon fibre
components to be easily separated
during recycling.
However, these initiatives remain
largely experimental or small-scale.
Mainstream adoption requires
significant investment in specialised
recycling facilities, government
incentives, and unprecedented
Why action can’t wait
Addressing Scope 3 emissions
and composite waste transcends
compliance targets; it’s about
resource security and competitive
advantage. As regulations tighten and
customers demand transparency,
manufacturers with comprehensive
sustainability strategies will
differentiate themselves in an
increasingly conscious market.
The companies investing in these
solutions today are building the
infrastructure and partnerships
needed to thrive in tomorrow’s
circular economy. Those waiting
for perfect solutions may find
themselves overwhelmed by both
regulatory pressure and mounting
waste disposal costs.
Composite waste recycling remains
one of the biggest missing links
in the journey to net zero. But
with innovation accelerating and
collaboration increasing, that link is
finally being forged.
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