FY2015 CSR Website CSR > Site Reports > Worksites > Takaoka Plant

Toyama Prefecture was ranked overall as the number one (first place in the lifestylecategory) most livable prefecture in the "47 Prefectures Happiness Rankings - 2014 Edition"(Jitsuro Terashima, Supervisory Editor, Japan Research Institute, Published by Toyo KeizaiInc.), and is widely considered to be one of the most livable prefectures in the country. Theprefecture is commonly referred to as the “Home of Manyo” after the poet Otomo noYakamochi, an 8th century statesmanpoet who famously compiled the poetry collection“Manyoshu (Anthology of Myriad Leaves).” The founder of Takaoka was Toshinaga Maeda,
a 16th century samurai lord, and the area has been known for its unique Takaoka

Aerial view of the Takaoka
Plant

copperware and lacquerware. Along with its arts, the city has been the center of a thriving
commercial area in the Hokuriku District along the Sea of Japan.
The Takaoka Plant is situated along the Oyabe River, which runs north-south through the city. The plant was established in1956 to manufacture polyvinyl chloride resins and expanded as the mass production site for the product over a half century until
the company exited the business in 2008. During that time, the plant began producing such current mainstay products as®

®

hydrogenated nitrile rubber Zetpol , semiconductors etching gas ZEORORA , and the organic coating insulation material®

ZEOCOAT for electric devices. The plant also became home to the Precision Optics Laboratory and a medical laboratory,
establishing itself as the center of cutting-edge research and development at Zeon.
The plant is adjacent to a residential community and strives to ensure the security of the local community through daily
safety-assurance activities and regular emergency-preparedness training. At the National Industrial Safety and HealthConvention held in Toyama Prefecture in 2012, Zeon was recognized for its attitude to safety efforts and the results it has
achieved, and subsequently received a letter of appreciation from the Japan Industrial Safety & Health Association.
In 2015, the plant turns 59 years of age, but it is still well in its prime and all employees continue to strive towards excellencewith the spirit that the future of Zeon will be born in Takaoka. The plant will continue to listen carefully to the needs of the local
community to ensure the sustainment of an environment rich in harmony and co-prosperity.

The Takaoka Plant has evolved from a mass producer of polyvinyl chloride resins to an R&D-style plant focused on thedevelopment of cutting-edge technologies. The fact remains, however, that a quiet residential community sits just a step outside
the plant gate. With this in mind, Zeon takes into consideration the possible impact of new products tests and newly introduced
product materials on the local community from the R&D phase of product development, as it has done with the manufacturing ofits current products. Each and every employee of the plant understands the CSR Policy, and based on this policy they strive toensure Zeon has a reason for being from the perspective of the local community and can continue to make contributions to that
community and society as a whole.

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1. Reducing toxic chemical emissions
The plant terminated the manufacture of polyvinyl chloride resins in March 2008, and therefore the amount of emissions and*1

transfer of PRTR -regulated substances declined in fiscal 2008 to less than one-tenth the amount of the previous year. As partof the initiative to achieve zero emissions*2, the plant has newly installed equipment to collect organic solvents used in themanufacturing process and plans to reduce the amount used in stages going forward.
*1 Pollutant Release and Transfer Register
A database of hazardous chemical substances released into the environment and transferred off-site in waste. It provides the public with important information such as where and how muchpollutants are being emitted and transferred.
*2 Zero emissions
The establishment of systems that discharge no emissions into the natural world, and the fundamental idea behind such establishment.

Substances subject to PRTR law

2. Reducing industrial waste
In fiscal 2011, the Takaoka Plant achieved zero emissions of industrial waste by recycling all of the waste plastics, rubber, andsludge emitted from wastewater processing facilities, which were previously disposed of at external landfills. In fiscal 2013,
although new facilities began operating and there were changes to the environment, the plant achieved zero landfill waste.
Despite continuing to operate new facilities, the plant will study new ways to achieve 100% recycling and maintain zero landfill
waste.
Amount of Waste to Landfill-2-FY2015 CSR Website CSR > Site Reports > Worksites > Takaoka Plant

3. Reducing air and water pollution*1

Atmospheric emission from the plant's boiler, which uses heavy fuel oil A , is one of the environmental issues the plant has
been dealing with. Until now, the plant has controlled boiler emissions by creating appropriate operating conditions collectivelywith steam emissions inside the plant. From December 2013, however, the plant has switched from heavy fuel oil A to liquefied*2natural gas (LNG) , and is proceeding to drastically reduce CO2.
*1 Heavy fuel oil AA heavy oil classified as type 1 heavy viscosity under JIS standards.
*2 LNG
Liquefied natural gas. Emits less CO2 than many other fossil fuels when combusted and therefore is seen as a more environmentally friendly fuel.

CO2 emissions

SOx and NOx emissions-3-

FY2015 CSR Website CSR > Site Reports > Worksites > Takaoka Plant

Overall wastewater, COD, total nitrogen (TN) and total phosphorus (TP) discharge

4. Saving resources and energy
The plant has taken measures to conserve energy by means of energy-conserving, high-efficiency boilers, which began
operation in December 2013. The Takaoka Plant also leveled-out electricity consumption in fiscal 2014 by shifting the operationof high electricity usage equipment to off-peak hours in the morning. The plant plans to enhance energy-conservation evenfurther by involving all employees in conservation efforts.
Total amount of energy and Unit energy consumption index-4-FY2015 CSR Website CSR > Site Reports > Worksites > Takaoka Plant

4. Environmental Data
Takaoka Plant
Substances
Consumption (tons)
subject toAmount emitted (tons)
PRTR law
Industrial
Amount generated (before volume reduction)
waste(tons)
Amount generated (after volume reduction)(tons)
Amount sent to landfill (tons)
Atmospheric CO2 emissions (tons)
emissions
SOx emissions (tons)
NOx emissions (tons)
Soot emissions (tons)
Water resources (Industrial water + Ground water +3
Waterworks) consumption (1,000m )3Waste water Total waste water Discharge (1,000m )COD emissions (tons)
Total phosphorus discharge (tons)
Total nitrogen discharge (tons)
EnergyTotal consumption (crude oil equivalent, kL)
Unit consumption index (1990 = 100)
Production of PDR equivalent (tons)

FY2010210

FY2011223

FY2012125

FY201316

FY2014
21

0.2

0.2

0.1

0.0

0.0

3,458

4,730

4,882

12,494

8,794

671

529

535

1,056

437

174
24,208
7.0
140.4

0.0
20,132
6.8
15
0.7

3.4
23,329
9.5
190.0

0.0
22,546
3.2
130.0

0.0
20,8250.0
0.2
0.0

3,7323,808

4,052

3,732

3,848

3,050
9.2
0.2
10
9,750
94％
5,419

3,398
13.0
0.7
16
8,994
96％
4,866

4,408
14.3
0.5
19
8,868
103％
4,295

4,890
18.9
0.8
20
8,986
104％
4,433

3,322
12.7
0.3
14
8,290
92%
4,617

To support the realization of Zeon's Mid-Term Management Plan, SZ-20, and the enterprise blueprint for 2020, “Zeon creates*

the future today through the power of chemistry,” the Takaoka Plant is aiming to achieve a 100% yield rate . To achieve thisgoal, the plant will rely on science to analyze and visualize the underlying causes of quality anomalies as well as to devise
measures to address the problems.
* Yield rate:
The percentage of products rolling off the production line that pass quality inspections. A 100% yield rate means that no defective products were produced.

VOICE Stabilizing processes starts with visualizing processes quantitatively
The Takaoka Plant is undergoing transformation into a strongly versatile research anddevelopment plant by constructing cost-conscious and flexible production systems to realize
foreseen stability, safety, and technology in order to become a production base of newbusiness that will secure Zeon’s future. For this reason, we are putting the following policies
into practice.
1.

Achieve zero safety, environmental, and security benchmarks by establishing fail-safe,change management mechanisms.

2.

Realize zero process failures and loads by advancing production and technological

Makoto Watanabe,
Takaoka Plant Managerinnovations.
3.

Promote the development of new product manufacturing technologies by uniting the operating divisions.

4.

Enhance the supply-chain by promoting visualization and streamlining of operations.

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1. Contributing to the community through volunteer work
On June 1, 2014, some 200 employees and family members, representing not just theTakaoka Plant but the entire Zeon Takaoka Group, took part in the Himi Coastal Cleanuporganized by a local environmental organization. Also, on July 6, about 200 members of theGroup took part in the Fushiki-Kokubu Coastal Cleanup organized by the Takaoka-Fushiki
Beautification Volunteer Group and made a dedicated effort to clean up the beach. OnFebruary 22, 2014, we were given an environmental activity award by the “Himi City
Environmental Improvement Council” in connection to this coastal cleanup activity, which we
Himi Coastal Cleanup

have continually participated in since 2008.
In addition, in 2012 Aoba-cho—where the Takaoka Plant dormitory is located—marked 50years since its founding. To commemorate this event, employees joined local residents to plant six cherry blossom trees
alongside the dormitory. There is one cherry blossom tree on the property planted around 1957 that local residents lovingly callthe “Zeon cherry blossom.” The six newly planted trees will also surely be cherished by the local residents for many years tocome.
2. Interaction with the local community
Zeon Takaoka Group Summer Festival
The annual Zeon Takaoka Group Summer Festival was held on August 8, 2014. Employees, along with their family members
and local residents, were invited, bringing the total number of participants to over 550. On this day, a long snaking line of drinks
tents serving various meals, such as Shin-Takaoka specialties, Takaoka-style Totomaru okonomiyaki and Yakitori, helped tomake the event a great success. In addition, the day came to a great climax with all participants taking part in events, such as
karaoke competitions.
Futagami Manshou Kai
Employees from the Takaoka Plant actively take part in the Futagami Manshou Kai, an industry-academia-government
association in the Futagami district as a way to deepen ties to the local community.
Takaoka Manyo Festival
Takaoka City holds an annual Takaoka Manyo Festival. The Takaoka Plant takes part in theannual main event, the recitation of all 20 volumes of the “Manyoshu (Anthology of MyriadLeaves).” In 2014, the event was held on October 3, and 26 Zeon Takaoka Group
employees took part in the festivities, awakening their feelings of bygone days to recite manya Japanese poem at the gathering.
Employees reciting the"Manyoshu".

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