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HOW IT’S ALL MADE:
FROM CAPSULES TO COFFEE MACHINES

Our two NESCAFÉ® Dolce Gusto® factories are located in Spain (Girona) and in UK (Tutbury). From mid 2014 we will have another one in Germany (Schwerin).

For coffee machines production, we rely currently on a German company whose main manufacturing site is located in China (Shenzhen). A new manufacturing site located in Indonesia has started production early 2013, fully owned by the same German company.

Challenges

Throughout the value chain, social and environmental issues are considered. We want to make sure that, at every stage in the production of our machines and capsules, our suppliers meet requirements in responsible sourcing and production standards.

 

Our Goals

95% of our suppliers to be certified for Responsible Sourcing SMETA (Sedex Member Ethical Trade Audit) by the end 2013 and make sure we meet the Nestlé Supplier Code.

 

What We Are Doing

  • Nestlé developed the Nestlé Supplier Code, to ensure its suppliers respect and meet required standards in the areas of business integrity, environmental responsibility, labour, safety and health. This Code is complemented by the Nestlé Responsible Sourcing Guidelines for specific raw and packaging materials and is an integral part to any contract with suppliers. These guidelines are aligned with or go beyond internationally-recognised responsible production standards.
  • Our main original equipment manufacturers are part of the EICC “Electronic Industry Citizenship Coalition” - a third party collaborating with Nestlé to ensure compliance with Nestlé rules.
  • For coffee machines production, our own Engineering and Quality resources are located on-site on a daily basis to ensure a consistent output regarding machines Quality.

Expert Section

 

WHAT WE HAVE ACHIEVED

  • We currently have 75% of suppliers SMETA certified for Responsible Sourcing with an audit plan in place for the remainder by mid 2014.
  • All key packaging suppliers have been audited for Good Manufacturing Practices (GMP) and Food Safety.

Challenges

For NESCAFÉ® Dolce Gusto®, coffee roasting produces 2% of the greenhouse gas emissions generated during the life cycle of the coffee cup. Other environmental impacts during production concern water (0.5% of water consumption during the full life cycle), energy (3% of energy consumed during full life cycle) and waste.

 

Our Goals

Improve environmental impact, such as water and energy consumption, greenhouse gas emissions and waste. NESCAFÉ® Dolce Gusto® factories will contribute to Nescafé’s targets to reduce energy consumption per ton of product by 20% (between 2010 and 2020) and for the same time period, to reduce water consumption per ton of product by 30%. NESCAFÉ® Dolce Gusto® factories will also contribute to Nestlé’s targets to reduce greenhouse gas emissions per ton of product by 35% (by 2015 vs. 2005), and, for the same time period, to generate zero waste for disposal in at least 10% of our factories.

 

What We Are Doing

The Nestlé Environmental Management System (NEMS) has been implemented throughout the Company since 1996 and applies to NESCAFÉ® Dolce Gusto® factories

 
 

WHAT WE HAVE ACHIEVED

  • Our factories are certified according to ISO 14001:2004 (International standard on environment management), ISO 9001:2008 (International standard on quality management), ISO 22000:2005 (International standard on food safety management), and OHSAS 18001:2007 (International standard on site health and safety management) standards.
  • Our factory buildings are in line with environmental standards: Girona achieved the LEED Certification (Leadership in Energy and Environmental Design from the United States Green Building Council), Tutbury the BREEAM certification (BRE Environmental Assessment Method) and our target is to obtain the Gold LEED Certification for Schwerin.

Expert Section

Challenges

Our capsules have been designed to regulate the water pressure according to the drink you choose. It is a sophisticated technology, which also optimises the amount of coffee used. However, we are aware that capsules generate, as such, an additional environmental impact and waste. In addition, for NESCAFÉ® Dolce Gusto® capsules, capsule manufacturing and packaging contributes to 24% of the total life cycle greenhouse gases emissions (36% of non-renewable energy and 14% of water used).

 

Our Goals

Lower greenhouse gas emissions from capsule and packaging production by 7% between 2010 and 2015, by improving their design and manufacturing.

 

What We Are Doing

  • We work actively to optimise the weight of materials in our capsule whilst ensuring our products are still safe and of the best quality.
  • We are working to develop with our suppliers plastic materials made from responsibly managed with an improved environmental performance.

WHAT WE HAVE ACHIEVED

As yet, there is no definitive results on the overall impact these actions have in our bid to improve our environmental performance but we are continuing to explore alternative materials and technologies.

Challenges

Our coffee machines (machine materials, manufacturing and packaging) are responsible for 8% of the total life cycle greenhouse gases emissions (9% of non-renewable energy and 4% of water used). The overall share of the environmental impact of each machine depends a lot on its life span.

 

Our Goals

Improve the overall environmental performance of the machines by increasing their energy efficiency, improving materials recyclability at each machine’s end-of-life and reducing the amount of materials required to produce a machine.

What We Are Doing

  • Optimised machine components to reduce waste during the manufacturing process (eg. avoiding painted parts, reducing sub-assembly)
  • Improving machine recycling with less parts and making them easier to disassemble. This is helped by the optimising of the machine components as well.
 

WHAT WE HAVE ACHIEVED

Our quantified results regarding energy efficiency are presented in the section "energy efficiency".

Challenges

Packaging and capsules manufacturing are responsible for 24% of the total life cycle greenhouse gases emissions (36% of non-renewable energy and 14% of water used).

Our Goals

Reduce the greenhouse gas emissions created by the packaging and capsules by 7% between 2010 and 2015.

 

What We Are Doing

  • Our capsules are simply packed in recyclable cardboard boxes.
  • In our machine packaging, polystyrene has been replaced with paper pulp tray, which is made from renewable resources that can be recycled.
 

WHAT WE HAVE ACHIEVED

As yet, there is no definitive results on the overall impact these actions have in our bid to improve our environmental performance but we are continuing to explore alternative materials and technologies.