Life Cycle Inventory
Life Cycle Inventory
Life Cycle Inventory
Jason Ord
Tom DiCorcia
FALL 2005
University of Michigan
Acknowledgements
The authors would like to thank the following individuals for providing assistance:
I. Introduction
In selecting materials, product engineers have been trained to optimize quality, cost and
delivery. If the cost of a material reflected the environmental impact of its use, then
traditional design methodologies would yield products that would have a low impact. In
fact, this is not the case. Material costs usually do not include most of the environmental
costs associated with their extraction, processing of by-products and eventual disposal.
Life Cycle Assessment (LCA) is a powerful tool for measuring the environmental
impacts that otherwise may not be adequately accounted for. Armed with this
information, product engineers can make material and process selections that can make a
product more environmentally friendly, which besides being a generally good thing
can be of considerable economic value. Businesses, institutions and consumers are
increasingly evaluating products and vendors on their environmental performance.
Access to entire markets can depend on meeting legislated environmental design
standards.
A complete LCA includes a life cycle inventory, an analysis of the environmental
impacts, and an analysis of potential improvements. The life cycle inventory defines the
materials and energy associated with a product over its life cycle from extraction of the
raw materials, throughout its useful life, to eventual reuse, recycling or disposal at end of
life. See the figure below for a visual explanation of the life-cycle inventory [1].
energy water
materials recovered
raw material materials
gathering & manufacturing use end-of-life
processing recovered
energy
water
effluents airborne solid waste
emssions
5.2.1 Polymers
The printer uses polymers for its covers, primary structure, and mechanical parts. The
two most common polymers in printer we analyzed are primarily high-impact-
polystyrene (HIPS) and acrylonitrile-butadiene styrene (ABS). In order to make this
study more tractable, the printer plastics not ABS or HIPS were assumed to be ABS for
modeling purposes. 86% of the polymers in the printer are recyclable, where the others
are not due to the presence of fillers. The Boustead database had codes for the ABS and
HIPS, but no manufacturing codes such as palletizing and injection molding. Thus, the
intermediate material processing, packaging, and shipping are not included in the scope
of this report.
5.2.2 Metals
The printer employs galvanized steel sheet-metal for structure, plated steel shafts, copper
(in the motors) and some aluminum. All of this material is considered recyclable,
although the copper in the motors could be considered a knock-out element that would
inhibit steel recycling. Again, the Boustead database had codes for all three metals raw
materials but nothing for the processing, packaging, and shipping and thus were not
included in this report.
5.2.3 Electronic Assemblies
There are surprisingly few published LCAs for electronic products particularly for
PWB assemblies and electronic components. PWB and electronic components are not
modeled in the Boustead database used for this printer LCA, so we turned to published
papers and industrial sources to estimate inventory flows for the electronic assemblies in
the printer. The information is not comprehensive and what we were able to collect does
not neatly align with Boustead, but the affect of these distortions on the overall LCA for
the printer should be small as the weight of the electronic components make up just 3%
of the printer weight. Even so, we chose not to ignore the electronics because their
environmental impact can be disproportionate to their weight.
The electronics in the printer consist of six printed wiring board (PWB) assemblies
totaling 256 grams. These are all lead-free assemblies. The circuit boards are made of 1.6
mm thick epoxy coated glass fiber cloth laminate plated with copper. This is consistent
with standard FR4 laminate a very popular substrate. Through a complex, wet process
of masking, lithography and plating, electronics manufacturers create a printed circuit
board (PCB) from the un-patterned laminates. The epoxy (polyamide resin) may be
mixed with a brominated flame retardant. Standard FR4 boards come in one ounce and
two ounce copper referring to the amount of copper foil per square foot. Some of this
copper is stripped away and additional copper is plated on to form the circuit pattern. The
total estimated weight of copper in these circuit boards is 11.9 g. Based on industry
average figures provided by the Printed Wiring Board Resource Center (PWBRC) water
used to make this printers boards totaled 8 liters.
In this printers assemblies, small electronic components are surface mounted and larger
components are mounted to the boards using through-holes. The equipment manufacturer
Vitronics estimates that wave soldering consumes 0.000202446 kWh/cm2 of PWB area.
This is the figure for lead-free solder and VOC-free flux which are environmentally
preferable, but require more energy in process.
Connecting wires and cables in the printer were measured, and contain 88 g of copper.
There is an additional 17 g of copper in two coils and two transformers mounted on
circuit boards.
The passive components mounted on the PWBs are ignored. There are 16 semiconductors
of varying size and type. All use plastic packages. Williams published an oft cited paper
that highlighted the fact that input materials for a semiconductor have a mass that is many
times the weight of the finished product. We used figures from this paper to estimate
some of the major inputs for the semiconductors in the printer. Some of these figures
have been questioned, but alternative figures are not available.
For all of the electronic assemblies we obtained the following total inputs, which were
entered into Boustead:
Major Inputs
(electronics)
Process Electric (MJ) 52.5
Process Water (l) 150.5
Copper (g) 121.8
Epoxy (g) 34.6
Glass (fiber) (g) 22.0
For supporting information please refer to the electronics section of the appendix.
5.2.4 Printer Packaging
The printer packaging consisted primarily of a cardboard box, along with paperboard and
polystyrene restraints. In addition, the printer packing included polycarbonate (in the
form of a compact disc), and paper (users manuals). All of these items were modeled
with the limitations described in the polymers section. The details of the paper modeling
will be described shortly.
5.2.5 Printer Shipping
Since we did not know the final assembly location for this particular printer, we assumed
it was manufactured in Tianjin, China, which is an industrial city near Beijing. We
included in this model an estimate of the container-shipping from a port near Tianjin to
Oakland, California.
5.3 Use Phase
As is typical of products that consume materials and energy, much of the environmental
impact for these printers involve the use phase. The three primary aspects of a printers
use phase are paper, ink cartridges, and electricity. We assumed in this study that the
printer is used in the United States, and thus used average United States figures for the
energy generation inventories.
5.3.1 Consumables
InkJet printers are machines for producing printed pages, and they unavoidably consume
paper and ink throughout their useful life.
5.3.1.1 Paper
Printer paper was not included in the Boustead model, but information suitable for the
inventory was collected from other sources.
5.3.1.2 Ink Cartridges
The cartridges in this study are simplified to consist of polyethylene terephthalate (PET)
glass-filled polyester and electronics. The estimates of these materials are subject to the
same polymer and electronics modeling constraints listed previously. The ink is not
included in the scope of this study due to the analytical complexity of reducing it to its
constituent elements and the general lack of information about the material flows
associated with those elements.
5.3.2 Energy Use
Inkjet printers are energy consuming products. Although this study uses accurate
information for the energy consumed by the printers during the different modes of
operation printing, standby, and sleep mode we make several assumptions regarding
the average use profile described in more detail later in this report.
VI. Results and Discussion
VI.1 Outputs Reported
For each functional unit of 100 pages printed, we provide the amount of lifecycle
resources expended. We track 11 items in four categories described in the table below.
We chose these items because they are significant factors in the planets ecology.
Units per
Main Output Category Sub-categories
100 pages
Energy/CO2 Energy MJ
CO2 Equivalent 1EE4 mg
Air Emissions Dust (PM10) mg
CO mg
SOX as SO2 mg
NOX as NO2 mg
Hydrocarbons mg
Water Emissions BOD Biological Oxygen Demand mg
COD Chemical Oxygen Demand mg
Raw Materials / Solid Waste Raw Materials mg
Solid Waste mg
The electricity consumed, the weight of paper used and the number of ink cartridges
consumed were derived from the base case use assumptions. Electricity and paper weight
were directly entered into Boustead. The ink cartridge was broken down into its materials
and the weights of these were entered into Boustead.
The weights of all non-consumable materials in the printer were put into the production
subcategory. This category was further subdivided into additional categories, including:
Production Printer Mechanical The resources expended in production of the non-
electronic components of the printer, but not including the packaging, shipping or
consumables.
Production Printer Electronics The resources expended in production of the electronic
components of the printer, including the electronic circuit board (PWB) assemblies,
power supply, power cords, and all cabling, but not including electronic components in
the consumable ink cartridges.
Production Printer Shipping and packaging The resources expended in production of
the packaging and transport of the printer to its user.
Use Electricity Electric energy consumed in operation of the printer following the
base case assumptions.
Use Paper Paper consumed in operation of the printer following the base case
assumptions.
Use Cartridges Ink cartridges consumed in operation of the printer following the base
case assumptions.
The following report sections present the results of our analysis with discussion.
VI.3 Base Case: Energy and CO2 Equivalent
This section examines energy consumed and CO2 equivalents emitted in the production
of the printer and also its consumables electricity, paper and ink cartridges.
120
100
80
Production
60 Use
Overall
40
20
0
Total Energy (MJ) CO2 Equivalent (1E4 mg)
Figure XXA shows that the use phase dominates the lifecycle energy consumed. The CO2
emissions, as expected, are also highest for the use case, but the use phase for CO2 does
not dominate the production phase to the extent it does for energy consumed.
In figure XXB, we see that paper consumed in the use phase provides a negative
contribution to CO2 equivalent emissions. This explains why the use phase is not as
dominant for CO2. The negative CO2 emissions surprised us, and although we tried to
get an explanation for this phenomena from the Boustead software group (who were
generally very helpful throughout this process) we were unable to obtain one as of this
writing. One possible explanation is that the Boustead model assumes that the trees cut
for the paper are replaced with new trees which consume greater amounts of CO2 than the
mature trees cut down.
Energy and C02, Base Case (per 100 pages printed)
150
100
-50
-100
VI.4 Base Case: Air Emissions
This section examines the pollutants emitted to the air in the production of the printer and
also its consumables electricity, paper and ink cartridges.
14000
12000
10000
8000 Production
mg
Use
6000 Overall
4000
2000
0
Dust (PM10) CO SOX as SO2 NOX as NO2
The figure above shows that the use phase dominates the lifecycle air effluents in every
category reported here. In the figure below, we see SOX is at least as much caused by
paper consumption as it is by electricity consumption. On the other hand, NOX is mostly
a product of electricity consumption. Paper consumption is also associated with most of
the particulate generation.
Air Emissions, Base Case (per 100 pages printed)
5000
4500
Production- Printer Mechanical
4000
2500
Use- Electricity
2000
Use- Paper
1500
Use- Cartridges
1000
500
0
Dust (PM10) CO SOX as SO2 NOX as NO2
VI.5 Base Case: Water Emissions
This section examines the pollutants emitted to water in the production of the printer and
also its consumables electricity, paper and ink cartridges.
8000
7000
6000
5000
Production
mg
4000 Use
Overall
3000
2000
1000
0
COD BOD
The figure above shows that the use phase highly dominates the lifecycle water effluents,
and that Chemical Oxygen Demand seems to be much more of a problem than Biological
Oxygen Demand. In figure below, we see that paper consumption is, by far, the largest
cause of Chemical Oxygen Demand.
Water Emissions, Base Case (per 100 pages printed)
7000
6000
Production- Printer Mechanical
Use- Electricity
3000
Use- Paper
2000
Use- Cartridges
1000
0
COD BOD
VI.6 Base Case: Raw Materials and Solid Waste
This section examines the materials used and solid waste generated related to the
production of the printer and use of its consumables electricity, paper and ink cartridges
Raw Materials and Waste, Base Case (per 100 pages printed)
2500000
2000000
1500000
Production
mg
Use
Overall
1000000
500000
0
Raw Materials Solid Waste
The figure above shows that the use phase highly dominates the weight of total raw
materials consumed.
In the figure below, we see that paper consumption is, by far, the greatest contributor to
raw material depletion and solid waste production.
The amount of solid waste is greater than the amount of raw materials used, because
primary material and industrial waste is generated during the process of extracting raw
materials.
Raw Materials and Waste, Base Case (per 100 pages printed)
1600000
1400000
Production- Printer Mechanical
1200000
Production- Printer Electronics
1000000
Production- Printer Shipping and
Packaging
mg
800000
Use- Electricity
600000
Use- Paper
400000
Use- Cartridges
200000
0
Raw Materials Solid Waste
VII. Improvement Scenarios
This section addresses the question of what could be done to reduce the environmental
impact of using this inkjet printer. The two largest contributors to inventory categories
are paper consumption and electricity consumption both during the use phase.
Paper clearly dominates in raw materials consumption and water emissions. Paper use
also is a major contributor to SOX and particulate air emissions, as well as solid waste.
Electricity use dominates greenhouse gas production, and is the primary cause of SOX /
NOX air pollutants. Not surprisingly, electricity use is also a major contributor to the total
energy consumed about equal to that for paper.
160
140
120
100
Overall Base
80
Overall Duplex
60
40
20
0
Total Energy (MJ) CO2 Equivalent (1E4 mg)
14000
12000
10000
8000
Overall Base
mg
Overall Duplex
6000
4000
2000
0
Dust (PM10) CO SOX as SO2 NOX as NO2
Water Emissions, Base Case (per 100 pages printed)
8000
7000
6000
5000
Overall Base
mg
4000
Overall Duplex
3000
2000
1000
0
COD BOD
VII.2 Reduction in Electricity Use
In our base case we assumed that half of printer users would leave their printer power
switch on all of the time, and half would turn their printers power switch off at nights
and on weekends. Even when in so-called standby mode that is power switch on, not
printing this printer draws 5.9 watts of power. The printer is not designed to go into a
sleep mode after printing because it takes some time to reset itself if power is cut, and this
delay could affect customer satisfaction.
Notwithstanding the problems with start up delays, Life Cycle Inventory outputs were
recalculated assuming that the printer was turned off whenever it was not printing. This
reduced energy scenario is probably not achievable given customer desires and the price
level of this printer, but this extreme case provides a good test case should future
technology permit a low cost printer to go into very low power standby when not
printing.
The chart below shows that total energy consumption for the low power mode (identified
as off) is 32% lower than our base mode. The improvement for greenhouse gas
emissions was dramatically better a reduction of 92%. The total energy reduction drop
is not as significant as the CO2 drop because the feedstock energy of the paper is also a
significant contributor to total energy.
120
100
80
Overall Base
60
Overall "Off"
40
20
0
Total Energy (MJ) CO2 Equivalent (1E4 mg)
VIII. Sensitivity Analysis
Although the bulk of the printer and consumable materials had codes in the Boustead
database, there were some components, materials and processes that were not in the
database. In these cases either a reasonable substitute was entered, or, in some cases, the
component or material was omitted. To test the impact of these substitutions and
omissions on our overall conclusions, we performed some sensitivity analysis.
VIII.1 Sensitivity Analysis Production- Printer- Electronics
Electronic components and electronic fabrication processes, in particular, were not well-
represented in Boustead. Electronic components make up about 13.6% of the total weight
of the unpackaged printer, but only 1.5% of the weight of the paper consumed over a
typical printer lifetime. To better understand the sensitivity of our results to different
input values for the electronics we recalculated the LCI outputs two times and plus and
minus 50% of our nominal (estimated) impact from the electronics in the printer.
15%
% Change in Total CO2 Equivalent
10%
5%
0%
-50% 0% +50%
-5%
-10%
-15%
% Change of Total Production Electronics Inventory
The figure above shows that the parameter in the model most sensitive to production
electronics, total equivalent CO2, changes about 10% with a 50% change in the total
production electronics inventory. Considering that it is likely we under-estimated the
electronics inventory, this sensitivity is important but not great enough to invalidate our
model for the purposes intended.
VIII.1 Sensitivity Analysis Production- Printer Mechanical
We feel that we were able to do a reasonable job breaking down the printer mechanical
items into material inventories, albeit with some simplifying assumptions and the
inability to model processes such as injection molding and stamping. However, the
sensitivity analysis below shows that the portion of the model most sensitive to the
production mechanical phase only swings 6% when the entire mechanical inventory is
changed 50%. Thus, the mechanical modeling is adequate for our models goals.
8%
6%
% Change in Total CO2 Equivalent
4%
2%
0%
-50% 0% +50%
-2%
-4%
-6%
-8%
% Change of Total Production Mechanical Inventory
Finally we tested our models sensitivity to the assumption that one printer is used for
every 7500 pages. We tested the models response at a printer life of 750050%. This is
a large turn on a significant knob, so we expected some dramatic results. First we looked
at the most sensitive parameter to production, total equivalent CO2. This parameter
showed a large response, +35% given a 50% decrease in printer life in pages. This large
swing is likely due to the fact that the paper is modeled as having a negative CO2
contribution and keeps the use phase from completely dominating this category. A more
representative response is seen in the next figure, which shows a 15% increase in total
electricity consumed for a 50% reduction in printer life in pages.
Model Sensitivity to Pages per Printer Assumption
(Total Equivalent CO2)
40%
35%
% Change in Total CO2 Equivalent
30%
25%
20%
15%
10%
5%
0%
-5% -50% 0% +50%
-10%
-15%
% Change of Pages per Printer Assumption
20%
15%
% Change in Total Energy
10%
5%
0%
-50% 0% +50%
-5%
-10%
% Change of Pages per Printer Assumption
all
Semicon Process inputs / cm2 chips Source Notes
Fab Electricity (kWh) 1.5 11.87 Williams
Packgng Elect (kWh) 0.34 2.691 Williams
Water (l) 18 142.5 Williams 2 to 58 liters per cm2
Cu 4.947 Williams
Epoxy 2.886 Williams
PCB
Cu (g) 11.94 Ritchey
Glass (g) 22.02 Ritchey
Epoxy (g) 31.75 Ritchey
Water (l) 7.97 PWBRC
Sludge (g) 2.5 PWBRC
Major Inputs
(electronics) Notes
Process Electric (MJ) 52.5
Process Water (l) 150.5 Assume de-mineralized
Copper (g) 121.8 Assume electrolytic copper
Epoxy (g) 34.6
Glass (fiber) (g) 22.0
A2. Base Use Case Assumptions
Usage Calculations Base Case
Description Figure Note
Printer Lifetime (years) 3 Estimate, sensitivity analysis required.
Printer Lifetime (pages) 7500 Estimate, sensitivity analysis required.
Average Print Mode Speed 5 Slow to allow for photos, etc.
Printing Power (watts) 44.0
Standby Power (watts) 5.9
Off Power (watts) 0.6
Energy Useage Calculations
Weekly Pages Printed 48
Usage -- DB Codes
Database Code Description Value Unit
Fuel prod. core 22897 Electricity use - US 371 MJ
Mat. proc. core 4353 Mechanical printing paper 34 kg
A4. Inventory Tables
Printer Materials
Item Mass (g) Note
Metals (total) 910
Steel 696
Aluminum 165
Copper 49 Motor windings.
Plastics (total) 2179
Recyclable 1887
Non-recyclable 292
851 g of ABS includes other
ABS 163 categories
HIPS 1472
Other Plastics 544 Modeled as ABS.
Includes elastomers, etc.
Other, General (total) 144 Modeled as ABS.
Includes external cables and
Electronics 507 power supply.
Printer (total) 3740
Includes metals, recyclable
Recyclable Materials (total) 2947 plastic, copper.
Recyclable Materials (%) 79%
Cartridge -- DB Codes
Database Code Description
Mat. proc. core 4209 PET (high mol wt) production
Solid waste 8 Plastics (Process)
Solid waste 28 Electronics waste (Process)
SA core 24 Epoxy liquid resin
SA core 74 Electrolytic copper
Fuel prod. core 4297 Electricity use - CN
Mat. proc. core 3612 Demineralised water production
Printer Packaging
Item Mass (g) Note
Polystyrene 0.014 Shipping restraints.
Polycarbonate 0.015 CD.
Paperboard, Cardboard 0.881
Manual, etc. Waste code is
Office Paper 0.107 embedded in 4353.
Packaging (total) 1.017
Cartridge Packaging
Item Mass (g) Note
includes cartons, brochures, and
Paperboard 27 return envelope.
Hybrid plastic/foil pouch. Not
Other, General (total) 1 modeled.
Packaging (total) 28