Futamura reduces cellulose film carbon footprint

Futamura UK has reduced the carbon footprint of its cellulose films, demonstrating a continued commitment to sustainability and environmental responsibility.

Since 2019, Futamura has delivered a cumulative carbon saving equivalent to removing about 70,000 cars from UK roads for an entire year. This figure represents avoided CO2e emissions associated with lacquered (based on NatureFlexTM NVS) and plain film production between 2019 and 2025, calculated using IPCC AR6 GWP100 values from an independent third-party life cycle assessment from ERM. This resulted in an average reduction of 24 percent of the carbon footprint of their NatureFlex films.

Building on this success, additional major investments are now underway and scheduled for implementation by 2027/28. One example is the recently announced, internally known, Wet Sulphuric Acid (WSA) project. The installation will divert waste gases from the production process to generate a valuable raw material via an oxidation process. Heat generated as a byproduct of the chemical reaction will then be used to generate steam, the main form of energy utilized in the production process. Once operational, this asset will generate 15 percent of the total energy requirement of the Futamura site. These investments are projected to reduce Futamura’s CO2e emissions even further, the equivalent to removing an additional 4,000 cars from UK roads every year (based on 2025 production volumes). This represents another major step in reducing the carbon footprint of their products.

A contributor to recent carbon reductions has been the investment in a new compressed air system to strengthen energy efficiency, reduce carbon emissions and improve operational resilience. An independent air survey confirmed that this new system is outperforming expectations. To further enhance sustainability, Futamura integrated a heat-recovery system utilizing waste heat from the compressors to pre-heat thermotanks, reducing the steam required for the production process. The new system has proven highly dependable, with no major issues to date. These two improvements have delivered a reduction in Futamura’s carbon emissions of over 400 tCO2e per year.

Beyond large-scale investments, Futamura has implemented a range of targeted energy efficiency initiatives across its site. In 2022, air conditioning units in the administration block were reprogrammed to operate only when needed and within controlled temperature limits. Ongoing lighting upgrades have replaced inefficient fluorescent systems with modern LED technology. These improvements have reduced both energy consumption and the number of fixtures required, while maintaining or improving lighting quality. Currently, 80 percent of the site has been upgraded to LED lighting, which have led to a notable decrease in energy usage, achieving full payback within the first year.

Futamura conducted energy monitoring in their laboratories, which identified further opportunities for efficiency. Equipment such as ovens, previously operated continuously, are now used only when required. Weekend shutdowns and improved energy management practices have delivered a notable energy saving per year.

These combined efforts highlight Futamura’s holistic approach to sustainability, combining strategic investment, technological innovation and operational discipline to achieve
measurable environmental and economic benefits. Futamura remains committed to continuous improvement and to supporting its customers and partners in reducing environmental impact across the value chain.

Lucy Cowton, Futamura’s sustainability manager, commented: ‘The reductions in our operational and product carbon footprints reflect the dedication of our workforce and their commitment to continuous improvement. We see this as just the beginning, with future investments, such as the WSA plant, expected to reduce our operational emissions even further. We are incredibly proud of the progress we are making.’