025 gloria blue nega

Theme 1 : Enhancing Quality of Life

Our Challenge to establish Recycling-based Society

Development of our “Reman” Remanufacturing Business

Theme thumb %e3%83%aa%e3%83%9e%e3%83%b3%e5%b7%a5%e7%a8%8b%e5%9b%b3 %e8%8b%b1%e8%aa%9e

Our Challenge to establish Recycling-based Society

 

Development of our “Reman” Remanufacturing Business

Our “Reman” business involves the remanufacturing of used engines, transmissions, and other key components of construction and mining equipment into “Remanned” components. After confirming that these remanufactured parts are possessed of the same quality as newly manufactured components, we inject them back into the market. We currently promote the “Reman business at 14 “Reman” Centers worldwide.
We have established the Reman-Net, which connects Reman centers with one another, and K-WINS, which shares Reman technological information, and are actively using them for the global expansion of Reman operations and reuse/recycling. In addition, by using IC tags and two-dimensional codes, we manage the recycling history of remanned components to control quality and obtain durability data, and then provide feedback that is important for Komatsu to develop components with optimal lifespans.

  • Quality and performance that matches new components
  • Lower cost for "remanned" components
  • Reduced idle time for construction equipment because of adequate inventory of "remanned" components
  • Resource conservation and waste reduction through reuse and recycling of components

Changes in Reman Sales (base FY2004 = 100)

Reman Factories and Centers map


Reman Process

komatsu csr, env, corporate communication, 情報戦略本部, production division, Procurement Division, Development Division, Construction Equipment Marketing Division, ライフサイクル事業部, 地雷除去プロジェクト室

Reman Advances Resource Recycling
- A New Reman Plant Opens in South Africa to Strengthen Komatsu’s Recycled Components Business -

Komatsu opened a new Reman (remanufacturing) plant on the head office campus of Komatsu Africa Holdings (Pty)* in Johannesburg, South Africa. The plant will be a central hub for Reman’s remanufacturing business in Southern Africa and will provide high-quality, efficient recycled components to customers in the region.  The Reman Plant pursues the improvement of quality by clearly separating the areas, one area for the cleaning, disassembling, and testing of soil- and oil-smeared components from machines that have operated in mines to handle soil- and oil-smeared components, and the other for the assembly area which requires a high level of cleanliness. At the same time, the plant increases the readiness to efficiently undertake the entire process of receiving, cleaning, disassembling, testing, reassembling and shipping components, so that it can quickly provide high-quality remanufactured components. The Reman business also engages in 3R (reduce, reuse and recycle) activities to reduce waste by reusing and recycling components and contributes to resource recycling. The plant recycles and reuses about 14 of the 16 tons of components in the rear wheel transmissions of supersize dump trucks in service in Southern Africa. Annually, it remanufactures about 14 thousand tons of components.

  • The head office campus of Komatsu Africa Holdings is the collective term for the head office building, component depot, workshop, training center, Reman and many other discrete functions in a single location
Komatsu Africa Holdings’ new Reman building
Komatsu Africa Holdings’ new Reman building
Supersize electric dump truck
Supersize electric dump truck
komatsu csr, env, corporate communication, 情報戦略本部, production division, Procurement Division, Development Division, Construction Equipment Marketing Division, ライフサイクル事業部, 地雷除去プロジェクト室

 

Effective Use of Critical Materials in Products

Komatsu is working on the conservation and effective use of limited resources by reusing critical materials used in products, etc.
An increasing number of diesel engines, which are used in construction machines, are now equipped with exhaust gas processing devices to reduce the density of NOx (nitrogen oxide) and PM (particulate matter) in exhaust gases. The exhaust gas processing devices use noble metals as a catalyst to reduce the density of NOx and PM. To effectively use these resources, Oyama Plant in Japan, for example, collects the exhaust gas processing devices of construction machines that have been replaced and recycles the noble metals in them. They are also recycling other critical materials to make them reusable, ensuring their effective use and aiming to reduce the consumption of new critical materials.

env, production division

Effective resource utilization activity in production(Waste)

 

Activities to Effectively Utilize Resources in Production (1. Waste)

Komatsu promotes activities to reduce waste discharged from its production activities while also implementing "zero emission" activities to recycle and effectively use the generated waste.
We set a new medium-term global goal in FY2019 and began waste reduction activities mainly at bases with metal-casting processes, which generate approximately 70% of the entire waste volume. By turning waste into a valuable commodity and improving the methods for management of metal-casting waste sand, the waste generated per unit of production recorded a 35% reduction from FY2010 levels. After 2021, we will promote waste reduction activities primarily at foundries in Japan and overseas to meet new medium-term targets.

Item FY2019 FY2020 Target of FY2030

Index of waste generated per unit
(Reference year: 2010)

77

65

60

Major achievements in the previous fiscal year

《Japan》

  • Reduction of wood chips through packing mode improvements for items procured overseas
  • Expansion of activities to turn waste plastics, oils, etc. into valuable commodities
  • Expansion and promotion of waste sorting through the establishment of a recycling center
  • Recycling of forge scale

《Overseas》

  • Reduction of sand waste by sorting waste containing dust

Waste indicators in production activities

Amount of Generated WasteIndependent Practitioner's Assurancecheckmark

iAmount of Generated Waste (Scope of data: Komatsu Ltd. and the Komatsu Group manufacturing facilities)
Note: Partially revised as a result of revisions to past data.
env, production division

Recycling Forge-scale from Awazu Plant for Use as Raw Material for casting at Himi Plant

Recycled forge-scale (iron oxide)
Recycled forge-scale (iron oxide)

FForge-scale is the iron oxide that develops on the surface of a forged product during the forging processes performed by the Defense Systems Division at the Awazu Plant. In the past, this scale was entirely regarded as industrial waste and was disposed of accordingly. To reduce the amount of waste, the Himi plant focused on the fact that forge-scale is iron oxide and began to recycle it to use it as raw material in the Himi Plant’s casting processes. To use forge-scale (iron oxide) as raw material in the dissolution processes during casting, the AwazuHimi Plant began to simultaneously add aluminum and, through a thermite reaction (reduction of metallic oxide by aluminum), use the iron oxide as raw material for casting. This generates reaction heat when the aluminum reduces the iron oxide, and simultaneously saves energy in dissolution processes. Repeated experimentation with due consideration for safety led to the reduction of the entire amount of forge-scale produced annually to zero. This eliminated about 15 tons of waste that would have been generated by the Awazu Plant. Further, the reaction heat from thermite reaction helped to reduce the power consumption of the melting furnace by 27,000 kWh annually, leading to the reduction of CO2 emissions. The Awazu and Himi Plants cooperated with each other to achieve a significant reduction of the amounts of waste disposed and power consumed for heating.

komatsu csr, env, corporate communication, 情報戦略本部, production division, Procurement Division, Development Division, Construction Equipment Marketing Division, ライフサイクル事業部

Effective resource utilization activity in production(Water Resources)

 

Activities to Effectively Utilize Resources in Production (2. Water Resources)

In FY2019, we set new global mid-term targets for water usage in our domestic and overseas manufacturing facilities and launched initiatives to reduce water consumption.
In FY2020, We reduced water use per unit of internal manufacturing by 52% compared to FY2010 by reducing waste through the re-use of water within processes and daily management with a focus on sites in the Hokuriku area that use a lot of groundwater.
We will promote further water usage reduction activities domestically and overseas to meet a new medium-term target after 2021.

Item FY2019 FY2020 Target of FY2030

Index of water input volume per unit
(Reference year: 2010)

49

48

40

Major achievements in the previous fiscal year

《Japan》

  • Reduction of water leakage by renovating aged aboveground and underground water piping
  • Reduction of wash water through the use of membrane filtration devices

《Overseas》

  • Reduction of clean water consumption through the use of recycled water

 

Water Use Indicators in Production Activities

Water Input VolumeIndependent Practitioner's Assurancecheckmark

Water Use Indicators in Production Activities
Note: Partially revised as a result of revisions to past data.
env, production division

Using a Membrane Filtration Device to maintain the cleanliness of Cleaning Liquids longer(Reducing Waste and Water Consumption at the Koriyama Plant)

Membrane filtration device
Membrane filtration device

The Koriyama Plant operates about 39 washing machines to remove dirt and oil from components before assembly, coating and after the processing hydraulic machines and other pieces of equipment. This required the cleaning liquids to be changed regularly to maintain their cleanliness. The replaced liquids were collected as alkaline industrial waste, which accounted for nearly 30% of industrial waste of the entire plant. The introduction of a membrane filtration device enables the removal of oil and impurities within the membrane module while recirculating the cleaning liquid back to the tank. The filtered cleaning liquid maintains cleanliness, thus decreasing the frequency of changing the liquid and reducing the amount of alkaline industrial waste. The decrease in the frequency of changing the liquid also reduces water consumption and burdens on the water supply. In the plant’s activities, different washing machines share the membrane filtration device and the extended cleanliness of the machines’ cleaning liquids helps reduce environmental impact.

komatsu csr, env, corporate communication, 情報戦略本部, production division, Procurement Division, Development Division, Construction Equipment Marketing Division, ライフサイクル事業部

Recycling Water to Reduce Tap Water Consumption (Komatsu Indonesia)

Komatsu Indonesia’s wastewater recycling facility
Komatsu Indonesia’s wastewater recycling facility

Komatsu Indonesia believes that it bears social responsibilities in the efforts to provide clean water to support urban living in the rapidly growing city of Jakarta and to preserve water resources for future generations. For this purpose, Komatsu Indonesia recycled the wastewater, which is from the washing machines used in its production activities and from mosques, toilets, staff restaurants and other sources, by physical, chemical, and biological treatment to make it available for use as domestic water and commercial recycled water used in production activities. Since FY2012, Komatsu Indonesia has recycled wastewater under the management of the environmental safety division. During dry season, when it runs short of water, the company also uses water from the reservoir, provided that certain conditions have been met. This has helped reduce the consumption of city water in 2020 by 69% compared to 2010 and the percentage of water recycled has reached 73%.

komatsu csr, env, corporate communication, 情報戦略本部, production division, Procurement Division, Development Division, Construction Equipment Marketing Division, ライフサイクル事業部, 地雷除去プロジェクト室