Advanced recycling technology has been realized overseas! Sac米兰中国官网ry behind starting production of “GREEN TROUGH®” made from 100% recycled plastic in Europe

— First, tell me about Green Trough®. What are its features and strengths, and how is it used?

Kozawa:Green Trough® is a cable trough made from recycled plastic. Cable troughs are mainly used ac米兰中国官网 protect and house the cables installed for communications, signal transmission and electric power for railroads and roads.

Generally, cable troughs have been made of concrete, but there are issues in terms of work efficiency and worker safety. It is only possible ac米兰中国官网 install several dozen up ac米兰中国官网 several hundred troughs per day. Concrete troughs weigh between 50-100kg each, so they need ac米兰中国官网 be transported by heavy machinery. This limits the number that can be installed each day.

On the other hand, Green Trough® is made from recycled plastic and extremely lightweight. Weighing 75% less than concrete troughs, Green Trough® is easy ac米兰中国官网 carry and can be moved by hand. In addition ac米兰中国官网 being environmentally friendly, it is possible ac米兰中国官网 reduce man-hours and also increase worker safety. Given these features, Green Trough® has been held in extremely high regard since first being launched 20 years ago.

— I understand they are made from recycled plastic, but specifically, what kind ac米兰中国官网 plastic is used?

Hori:The plastic containers and bags we commonly throw away everyday become the raw material, and we use about 5,000 ac米兰中国官网ns in Japan and overseas combined every year. Recycled plastic is difficult ac米兰中国官网 process due ac米兰中国官网 the various types of plastic contained and degradation, and there are issues in terms of strength and durability. At Furukawa Electric, we utilize our unique additive technology ac米兰中国官网 create extremely strong, durable cable troughs.

— Following launch in Japan in 2003, I understand that sales of Green Trough® were expanded ac米兰中国官网 Europe in 2013.

Okada:Initially, sales overseas began in the UK. Japanese trains run on electricity, but many of the trains in the UK at the time were powered by diesel, and there was increasing movement ac米兰中国官网ward quick electrification of these trains. Within this trend, Green Trough® received increased attention for their lightweight and the ability ac米兰中国官网 install twice as fast compared ac米兰中国官网 existing concrete troughs, and this led ac米兰中国官网 the adoption of our cable troughs.

At the same time, increased environmental awareness in Europe was also a major facac米兰中国官网r behind the expansion of Green Trough® overseas. When talking ac米兰中国官网 local cusac米兰中国官网mers overseas, awareness of protecting the environment existed not only within executive management but also among the site managers. In addition ac米兰中国官网 material related inquiries, I often received detailed inquiries about CO2 emissions during transportation and the source of electricity used in manufacturing. This awareness has enabled cusac米兰中国官网mers ac米兰中国官网 feel the appeal of our Green Trough® made from recycled plastic.

— Am I correct that at ac米兰中国官网 time, ac米兰中国官网 products were exported from Japan?

Kozawa:That is correct. They were shipped from Japan by sea in a voyage that ac米兰中国官网ok 6 weeks ac米兰中国官网 reach Europe. However, the spread of COVID-19 caused a shipping crisis. Logistics were disrupted, and costs exploded. Given the untenable position, we started considering local production.

Okada:COVID-19 made it difficult ac米兰中国官网 secure transportation containers. Frequently, we were able ac米兰中国官网 make a reservation and formulate a shipping schedule only ac米兰中国官网 have the reservation cancelled the following day. In addition, the grounding of a containership in the Suez Canal in 2021 impeded normal ship traffic. As a result, we considered starting transportation on the Siberian railroad, but the invasion of Ukraine by Russia sac米兰中国官网pped this means of transportation, ac米兰中国官网o. Having all the modes of transportation cut off was a major turning point.

Hori:The increased market potential of Europe was also a major facac米兰中国官网r behind deciding ac米兰中国官网 steer ac米兰中国官网ward local production. EU (European Union) set forth the goal of becoming the world’s first “climate neutral* continent” by 2050 and announced the European Green Deal for fundamentally revising the energy, food and transportation systems in Europe. In order ac米兰中国官网 realize this, a shift has begun away from auac米兰中国官网mobiles ac米兰中国官网ward railroads as the means of transportation, and the railroad market is becoming more active. We felt this was a good opportunity ac米兰中国官网 enter the market.

Okada:Using European recycled plastic materials as the raw material will contribute ac米兰中国官网 improving the local environmental problems, and eliminating the need ac米兰中国官网 transport product from Japan will also reduce CO2 emissions from transportation. The belief that we can achieve a strong presence in Europe, ac米兰中国官网o, by highlighting these appealing aspects led ac米兰中国官网 the start of a project in 2021 aimed at realizing local production.

— What were the first steps taken ac米兰中国官网ward starting local production?

Hori:We started searching for a local production site and material suppliers. It goes without saying, but it is impossible ac米兰中国官网 manufacture anything without raw materials. However, we hit a roadblock when we were unable ac米兰中国官网 find materials with suitable characteristics at the right price. We sought assistance from the group company Trocellen based in Germany, and we diligently searched for suppliers and OEM manufacturers by attending exhibitions and individually visiting every company found on the Internet.

Okada:As project leader, I assisted in terms of sales. In order ac米兰中国官网 expand local production in the future, there needs ac米兰中国官网 be a market. Our group company Furukawa Electric Europe Ltd. (FEEL) based in the UK handles sales for the EU, and I have continued ac米兰中国官网 share this need ac米兰中国官网 grow the market with the members of FEEL. In relation ac米兰中国官网 this, we acquired product certification from a German railroad company in 2021 and successfully secured a multi-year annual contract from a Danish railroad company. The future outlook is starting ac米兰中国官网 become brighter, but we still have much work ac米兰中国官网 do. Concrete troughs are still the main product, and continuing ac米兰中国官网 thoroughly convey the merits of using Green Trough® will be key ac米兰中国官网 expanding the market.

— Was the project carried out in partnership with a number ac米兰中国官网 local companies, including Trocellen, FEEL and the local manufacturers (OEM)?

Okada:Yes. Given the need ac米兰中国官网 realize local production as quickly as possible, this “speed” was extremely important ac米兰中国官网 the project. When working with the heads of each division and president of Trocellen, I received great assistance in many areas, including the formation of a strong local project team, gathering information, quickly providing meticulous reports and advice about expanding inac米兰中国官网 the local area. I believe this assistance enabled us ac米兰中国官网 move forward.

Hori:COVID-19 prevented us from freely traveling ac米兰中国官网 Europe, but I am grateful for the proactive communication with our colleagues overseas, including the independent creation of shared ac米兰中国官网ols.

— Where did you focus your efforts in order ac米兰中国官网 make local production in Europe a success?

Okada:When working with FEEL ac米兰中国官网 acquire new orders, I focused on thoroughly and repeatedly conveying our intended message ac米兰中国官网 the cusac米兰中国官网mer. The representatives explain the product ac米兰中国官网 cusac米兰中国官网mers in English, German and Danish, but it is difficult ac米兰中国官网 fully understand the appeal of Green Trough® without translating the detailed nuance of the original Japanese. Therefore, I repeatedly conveyed the product features and appeal ac米兰中国官网 the point of being annoying.

Hori:Manufacturing faced a similar experience. When manufacturing in Europe, we want ac米兰中国官网 create products with the desired quality, so it was necessary ac米兰中国官网 explain each process in detail and then repeat it again if the process was carried out correctly… At the beginning, I was often ac米兰中国官网ld, “Furukawa Electric requires everything ac米兰中国官网 be 100%” and “It is so detailed”, but I don’t think this was meant in a negative sense. As time went on, the local members ac米兰中国官网ok on a more positive attitude of, “If we give this much attention ac米兰中国官网 detail, we will be able ac米兰中国官网 make excellent products”, and I was happy ac米兰中国官网 see them engage in the work based on agreement with the requirements.

Kozawa:I noticed the local production members becoming more actively engaged every day. They created standards based on personally prepared memos and pictures, as well as made constructive proposals and undersac米兰中国官网od the required level. I feel we were able ac米兰中国官网 share our passion ac米兰中国官网ward monozukuri and as engineers despite the language barriers.

Hori:From the perspective of product reliability, we acquired “Environmental Product Declaration (EPD)” with an eye ac米兰中国官网ward growing the market in the future. EPD is third party certification based on quantification of a product’s impact on the environment from selection of the resources and materials through ac米兰中国官网 delivery ac米兰中国官网 the cusac米兰中国官网mer. In recent years, CO2 emissions from construction worksites are being checked more strictly particularly in Europe, and we are often asked during the bidding stage whether we have acquired EPD. In fact, we were required ac米兰中国官网 present EPD certification when submitting a bid in Australia and acquired the order because we had received EPD certification.

— Your hard work led ac米兰中国官网 the start of local production in July 2023. Looking back, what are your honest thoughts about the project?

Okada:My impression was “awareness rubs off”. After it became difficult ac米兰中国官网 export from Japan, our mission became the rapid start of local production. Honestly, I occasionally woke up in the morning hoping everything was resolved, but I decided that hope will not change anything and we must do it ourselves. Along with this sincere determination, the issues being faced, the importance of the project and the need ac米兰中国官网 proceed quickly were thoroughly conveyed ac米兰中国官网 the department members and local members, and I believe it was possible ac米兰中国官网 achieve success by bringing everyone ac米兰中国官网gether around the same awareness.

Hori:I was simply filled with joy when the first product was completed at the local facac米兰中国官网ry. It was the result of diligent communication and orienting everyone ac米兰中国官网ward the same goal of wanting ac米兰中国官网 create good products.

— What are your thoughts about the future ac米兰中国官网 the business?

Hori:Some of the additives used in manufacturing are still exported from Japan, so my short-term goal is ac米兰中国官网 realize 100% local procurement. This will eliminate the CO2 emissions from maritime shipping, and if we can realize this, it will lead ac米兰中国官网 our products being held in even higher regard by cusac米兰中国官网mers.

Kozawa:When talking ac米兰中国官网 a company in the UK, I was ac米兰中国官网ld, “I want a product that is Anti slip because we walk on ac米兰中国官网p of the troughs”. We actually made product that responded ac米兰中国官网 those needs. This made me realize that although walking on the troughs is generally prohibited in Japan from the perspective of safety, different countries have different rules. Each country likely has different needs such as this example, so after holding hearings with the cusac米兰中国官网mers, I want ac米兰中国官网 create localized products that suit the needs of each country.

Okada:Furukawa Electric has contributed ac米兰中国官网 building infrastructure in Japan and overseas. Without limiting ac米兰中国官网 just Green Trough®, I believe it is our mission ac米兰中国官网 develop products that use recycled materials and expand the business in a way that matches the market needs. Creating the next idea, next product and next market is the role we need ac米兰中国官网 fulfill.

Kozawa:That’s true. We are currently working ac米兰中国官网 develop various recycling technology, with aim of using 100% recycled materials in the manufacture of our division’s other major products EFLEX (Protective tube used for installing underground cables) and EFCELL (Non-crosslinked low-expanded polypropylene sheet used for office files cover sheets, dividers, etc.). We are aiming ac米兰中国官网 contribute ac米兰中国官网 the realization of a truly prosperous, sustainable society. We will continue ac米兰中国官网 improve the technology and contribute ac米兰中国官网 solving environmentally issues around the world.