Circular Economy & Materials
We are accelerating circular solutions to develop material-efficient, energy-efficient, high-quality products that reduce our customers’ environmental impact and meet the needs of a sustainable built environment.
Our approach
We live in and depend on an interconnected world, with complex environmental, social, economic, and cultural systems. Damaging one element may have an unexpected impact elsewhere. We recognize the limits of our planet and that we must act more sustainably in order to meet increasing social and economic demands. As a leading manufacturer, dormakaba is committed to incorporating the latest product life cycle approaches and environmental technologies to continuously advance our product development and improve our own and our customers’ sustainability performance. This not only provides new opportunities for our design and manufacturing processes; it also addresses our customers’ expectations regarding environmentally friendly products.
We are aware that the sustainability of our products is essential for our success. The Product Sustainability department, under the Global Innovations function, acts as a competence center for all product clusters globally. It provides the right resources, skills, and expertise, and is responsible for shaping a state-of-the-art development environment for product sustainability. This includes, for example, developing Environmental Product Declarations, incorporating sustainability criteria into all product development-related processes, and elaborating guidelines.
Our global Environment Directive regulates minimum business standards on environmental management in manufacturing practices. It also regulates mandatory requirements on product circularity and eco design, including minimum energy efficiency and recycled content benchmarks for each product class. These have also been integrated into our global product development process.
The dormakaba sustainability commitment and life cycle approach are also integrated into our Product Design Manual.
Our activities
Product design with the circular approach
With an average lifespan of 40 to 50 years, buildings should ideally be constructed in a way that allows the required materials and natural resources to be used efficiently. We are dedicated to producing high-quality and reliable products and solutions, while also integrating our customers’ desire for environmentally friendly options. As a result, product design remains a core focus of our sustainability strategy, with an emphasis on energy consumption and carbon emissions during the product’s use phase, waste management, and recyclability at its end of life.
During FY 22/23 we achieved our target of covering all new product developments and optimizations using our circularity approach. We achieved this aim by developing an EcoDesign Specification Template, which has been mandatory for all new product developments since FY 23/24. The template is used as a single source of truth for sustainability criteria for every product development-related process within the dormakaba Group. Therefore, its use is mandated and described in our global product development guideline, the Adaptive Innovation Methodology (AIM) Directive. All local product development processes need to adhere to the AIM Directive. The EcoDesign criteria include guidelines on energy use, materials selection, longevity/durability, repairability, adaptability, and disassembly. The template also defines minimum values for the use of recycled content and how to design and select the product packaging. Further guidance and explanations for the implementation of the different EcoDesign criteria are provided in the Environment Directive.
In FY 23/24, we worked together with Key & Wall Solutions teams to include additional requirements based on their unique product portfolios as well.
Environmentally friendly packaging
For the packaging of our products, we mostly use paper, cardboard, wood and plastic. It is our aim to substitute packaging materials with more sustainable alternatives. By 2027 we want to use zero fossil fuel-based plastic in our packaging (baseline 223 tons in FY 20/21). We also aim to obtain 100% of the paper, wood, and carton from sources that are Forest Stewardship Council (FSC)-certified or similarly certified by other accepted responsible forestry schemes.
We collaborate with our suppliers to highlight the need for them to become certified under a responsible forestry scheme. In order to support our suppliers, we organize meetings together with FSC representatives to raise awareness and clarify questions related to the certification process.
In addition to FSC, we also accept the following standards for forest-based products: Sustainable Forestry Initiative (SFI), American Tree Farm System (ATFS), and the Programme for the Endorsement of Forest Certification (PEFC), as these are also accepted by the green building standard LEED (Leadership in Energy and Environmental Design). In FY 23/24, we were able to confirm that about 25% of our total paper, wood, and cardboard purchases are FSC (or similarly) certified.
We have included the above requirements in an updated Corporate Design Packaging Guideline. Additional new requirements include that preference must be given to water-based inks and adhesives and that plastic packaging should be recyclable and biodegradable. If plastic packaging is currently used, it must contain a minimum of 30% recycled plastic material. Plastic materials such as polystyrene, PVC, or fossil fuel-based plastics should be avoided, and fossil fuel-based plastics must be eliminated by the end of FY 26/27. The Corporate Design Packaging Guideline also includes minimum requirements on material declarations, such as how recycling codes should appear on the packaging.
Due to the ever-changing regulatory landscape, we are constantly adding new requirements to our Corporate Design Packaging Guideline to make sure we are compliant with all global and local laws. We welcome regulations that foster the use of environmentally friendly packaging. For example, since 2022, all packaging imported to Italy has had to carry a material declaration and recycling information. Also in 2022, France introduced a regulation to ban aromatic mineral oil hydrocarbons (MOAH) and saturated petroleum hydrocarbons (MOSH) in packaging and printing inks in two steps starting in 2023. A review with our main packaging suppliers from Germany and Asia confirms that we are compliant with the French law.
In 2024 the European Parliament adopted the Packaging and Packaging Waste Regulation (PPWR), which aims to contribute to a circular economy. The regulations touches on topics such as packaging take-back obligations and the reduction of packaging in landfills. Internally, we have already been working to support this latter requirement through our zero waste to landfill initiative in collaboration with Beyondly, which aims to eliminate waste to landfill by optimizing waste segregation and following the waste hierarchy, as well as finding partners that see a value in our residual materials.
Providing transparent information about our products
By providing transparency for our products regarding their sustainability performance, we secure our market position and offer added value to customers seeking green building certifications.
Material compliance
Since early 2021, components imported or sold in the European Union containing with Substances of Very High Concern (SVHCs) in a concentration higher than 0.1% have had to be reported in the SCIP Database created by the European Chemicals Agency. To be compliant with European regulations, we are continually uploading the required data on SVHCs to the SCIP Database. Furthermore, we adhere to the requirements of the RoHS Directive 2011/65/EU, which restricts the use of certain hazardous substances in electrical and electronic equipment.
In addition to adhering to the EU RoHS and REACH regulations and the Waste Framework Directive, we comply with California Proposition 65, TSCA (Toxic Substances Control Act of 1976), and PFAS regulations for products imported into and/or sold in the USA. The California Proposition 65 requires businesses to provide warnings to Californians about significant exposures to specified chemicals that cause cancer, birth defects, or other reproductive harm. The TSCA addresses the production, importation, use, and disposal of specific chemicals.
PFAS (Per- and Polyfluorinated Substances) chemicals are increasingly regulated due to their link to harmful health effects in humans and animals. Whereas the EU just started the process to further regulate the use of PFAS, several states in the USA have already enacted regulations restricting the use of PFAS in products sold in their markets, and increased restrictions and reporting are on the horizon.
Product declarations and green building certifications
We quantify and disclose a product’s environmental impact across its entire life cycle in our Environmental Product Declarations (EPDs), which are based on the international standards ISO 14025, 14040, and 14044. Our EPDs meet all mentioned standards to ensure that our environmental information is transparent, reliable, and credible.
dormakaba also offers various health-related product declarations, which transparently account for the materials found in our products. These take the form of Health Product Declarations (HPDs) or Building Product Declarations (BPDs), depending on local market requirements.
By 2027, we aim to double our sustainability-related product declarations/certifications, including Cradle to Cradle and for recycled content (baseline 170 in FY 20/21). We currently provide our customers with 322 such declarations and certifications, and we are well on track to meet this target.
Our product declarations are based on Life Cycle Assessments (LCA), which provide a reliable calculation of the environmental performance of a product. This includes the systematic assessment of the environmental impacts arising during the extraction of raw materials and all the way through the production, distribution, use, and end of life phases, which are quantified based on materials, energy consumption, transport routes, emissions, across the life span of the products.
There are two LCA approaches: cradle-to-gate and cradle-to-grave. The first approach considers all production stage modules: raw material supply, transport, and manufacturing. The latter covers all life cycle modules, which means that in addition to the cradle-to-gate stages, cradle-to-grave analyzes the building construction process, the product use stage, and end of life (i.e., the upstream value chain). We mainly use cradle-to-gate “with options” so that we can select the relevant upstream life cycle module(s).
Product information from environmental or health-related product declarations can help our customers attain the highest green building certifications, such as Leadership in Energy and Environmental Design (LEED). dormakaba publishes the product information on internationally recognized sustainability platforms such as the Sustainable Product Information Module (SuPIM) by the Institut Bauen und Umwelt (IBU, Institute for Construction and Environment). SuPIM provides all product-related sustainability data from the manufacturers for various building certification systems such as LEED, the German Sustainable Building Council (DGNB),”Bewertungssystem Nachhaltiges Bauen” (BNB, Evaluation System for Sustainable Construction), and the Building Research Establishment Environmental Assessment Method (BREEAM).
These are compiled in a data sheet and supplemented with the corresponding verification documents. For quality assurance purposes, IBU reviews the data uploaded on their platform. Such platforms provide transparent environmental and health information for users and ensure easy access to specific product data. By providing this level of product information, we seek to lower market entry barriers in the green building industry, enabling our inclusion in related bidding processes.
In FY 23/24, we became members of madaster, a platform that records and documents all materials and products used in buildings and infrastructures to create a comprehensive material database and that promotes a circular economy in the construction industry. Various information about our products is recorded on the platform, for example, material composition, material origin, recyclability and reusability, life cycle data, and information on product certifications and/or declarations. This material database acts as a digital identity card for every building, enabling seamless material traceability and creating a transparent picture of the resource consumption and environmental impact of a building. By no longer viewing buildings as finite resources but as sources of reusable or recyclable materials, we can significantly contribute to climate protection and the conservation of our natural resources.
Activities and key results regarding carbon emissions (Scope 1 & 2) and energy consumption during production.
Production with lower environmental impact
At dormakaba, we recognize that environmental responsibility is integral to producing world-class products. Besides adhering to environmental laws and regulations, we focus on improving our management of environmentally relevant processes and on monitoring and reducing our energy consumption, carbon emissions, water consumption, and effluents, as well as monitoring our waste disposal and recycling rates.
Responsible use of materials
Among the raw materials we use for our products, there are metals such as steel, brass, aluminum, nickel silver, and zinc, as well as gypsum board, glass, and plastics. Other important materials are wood, paper, and cardboard, which are made from renewable resources.
Since the primary extraction of metals from ore and the subsequent refining processes are resource-intensive, one key focus is to increase the use of metals with a high level of recycled content. As mentioned, our Environment Directive sets a minimum amount of recycled content for each material, including these metals. We also work with suppliers to help us obtain certifications on the recycled content of our products. In FY 23/24 we received 23 new recycled content certifications, issued by GreenCircle Certified, for all door closers manufactured in Singapore. This is in addition to the 16 certifications we have for door hardware manufactured in the USA.
Material use (in %)
Raw material use (in %)
Closed-loop processes
Several production sites focus on closed-loop systems in their material use. Manufacturing facilities recycle most internal scrap metal, either by reintroducing the material in their own processes or by selling it to a local recycler. Scrap material is also sent back to the original supplier, who then uses it to make our purchased materials, resulting in a closed-loop system. As an example, our manufacturing plant in Nogales (Mexico) is working on an initiative to return non-recyclable packaging to a vendor for reuse. Analysis of the amount of packaging to be sent back, setting up the collection points at the plant, and defining inspection and shipping processes are being carried out. Additionally, the facility is also separating scrap metal according to alloy. This methodology ensures a more efficient recycling process, and at the same time increases the purchase value paid by our recycling companies.
Waste management
We respect the universal human right to safe and clean drinking water and sanitation. Learn about our activities and key results regarding water and effluents management.
In addition to water consumption and effluents, waste management is of key importance during the electroplating, surface finishing, and painting processes. We work to minimize the volume and toxicity of waste from these operations through continuous improvement projects. Our filter systems ensure that potentially hazardous substances are not released externally. Toxic waste arising from painting and electroplating is disposed of as special waste. Certified disposal companies are commissioned to dispose of industrial waste and chemicals, and to recycle materials.
We monitor our waste by treatment method and waste type. At 73% by weight, the largest proportion of waste is scrap metal. In FY 23/24, approximately 89% of the waste stream was recycled, reused, recovered (including raw materials and energy recovery), or stored on-site.
Non-hazardous waste by type
(in metric tons)
Hazardous waste by type
(in metric tons)
Waste by treatment path
(in metric tons)
Waste intensity
(t/mCHF net sales)
The generation of different waste streams is an inevitable consequence of our operations, although by implementing the circular economy approach, we aim to send zero waste to landfill in our operations by 2027 (baseline 3,443 tons in FY 20/21).
In order to reach our zero waste to landfill goal, 33 manufacturing sites have been tasked with developing road maps for sustainable waste management. Additionally, six sites that account for a combined 67% of our waste to landfill baseline received one-on-one support, including an on-site waste audit and specific waste optimization action plan in collaboration with our external experts from Beyondly. The local management is provided with training, guidance, and advice, and they can share best practices with each other as part of regular meetings.
The zero waste to landfill initiative is aligned with SDG (Sustainable Development Goals) principles by minimizing waste generation and maximizing resource efficiency. The specific action plans include waste stream characterization, segregation to find waste value, diverting key materials from landfill waste, and identifying potential local partners and users of waste streams. Ultimately, this brings economic benefits as well, from cost savings on disposal fees to new revenue streams from recycling.
Local actions to reduce the amount of waste going to landfill were also taken place. Examples in FY 23/24 included:
- In our Chino (USA) plant, we established a policy where throwing out paper waste is banned. Together with an external shredding company, we installed four containers strategically located throughout the facility to increase paper recycling rates. Consequently, landfill waste was reduced by 57% compared to the previous financial year in our Chino plant.
- Our São Paulo (Brazil) site implemented a program for waste recycling and organic waste composting. Our waste is sent to certified recycling plants (paper and plastics), to qualified composting plants (gardening waste), and only a small amount will remain for landfill disposal. In comparison with the previous FY, this location reduced the amount of waste sent to landfill by 82%.
- In Australia, our facility in Hallam has optimized recycling and reduced landfill waste. Individual desk bins were eliminated and instead bulk recycling and waste bins are provided to increase recycling rates. Additionally, hand dryers were installed in rest rooms to eliminate the use of paper towels. Finally, filler packaging materials – such as air-filled plastic pillows and foam – were replaced with perforated cardboard waste. The cardboard waste was derived from incoming materials packaging, thereby finding a good way to reuse what would otherwise have been treated as waste. As a result, landfill waste was reduced by a whopping 75%.
- In Fougères (France), we are extending our storage area for waste recycling bins. For our scheme to implement a successful waste management system, recycling needed to be made as convenient as possible. The waste sent to landfill was reduced by 36% compared to the prior financial year.
- Our team in Singapore is conducting a recycling program to reduce waste in plant operations. This initiative is primarily focused on identifying the waste data sources in order to categorize the recyclable material. This strategy will allow dormakaba Singapore to increase its current recycling rate of 96.2%.
Take-back programs
Most of our products have a long life span of up to 20 years, but their purpose should not end after being uninstalled. Some of the components of our products can be reused, repaired, or reintroduced as raw materials back into the manufacturing cycle.
Collecting products and components from customers and partners requires collaboration between various dormakaba departments. Logistics, quality management, product development, and production are all important functions that should be involved. A take-back program is an extended product responsibility scheme, meaning that whoever introduces a product into a countryʼs market remains responsible for that product after the end of its life. Take-back programs have multiple benefits, such as stronger customer relationships, development of an alternative supply of critical raw materials, mitigated risks associated with hazardous materials handling, reduced environmental impact, and cost savings.
By 2027, we plan to offer extended producer responsibility take-back schemes for all products and packaging in the top ten sales countries.
Closing the loop – solutions for a product take-back program in Germany
In FY 22/23, we accompanied Masterʼs students from the KEDGE Business School’s “Business Transformation Program for Sustainability” program in France in developing a concept for take-back programs for nine countries, focusing on one top-selling product per country. Due to the complexity and the market immaturity for such programs, this financial year we established a strategic partnership with Resourcify, a waste management and recycling expert, to jointly develop product take-back programs in Germany, Switzerland, Austria, and the UK in the current and upcoming financial year.
As a kick-off for the program development with Resourcify, we have organized a workshop in Germany where dormakaba representatives shared their valuable insights from various departments including Product Development, Sales, Quality, and from our European Logistics Center (ELC), where there is already a take-back program in place. New products that are returned by our customers or brought back by our service technicians due to errors in delivery or over-ordering, go through a quality control at the ELC to determine if any of the components or the whole product can be reused.
Furthermore, we invited an important customer, Lindner, to share their experiences with their own product take-back scheme called LinLoop. The program is geared toward the take-back of ceiling and floor tiles and offers flexible return and rental options. At the workshop several great best practices were shared on logistics at construction sites, dealing with recycling firms and refurbishment and remanufacturing processes, and the contractual setup with customers including discount rates, as well as processes to resell these products on the market.
In Germany, door closers were chosen for initial assessment during the workshop, and the potential for reparability, refurbishment, and then recycling was analyzed. The next step for the project team is to analyze similar scenarios for other product groups, such as swing door operators, where there might be more opportunities for reparability and refurbishment due to their electronic chips and components.
Outlook
During the next financial year, we will implement a Product Scoring Model for sustainability, with the aim of assessing the environmental and social performance of our products against five overarching criteria and benchmark data in an objective manner. We will also continue developing sustainability-related product declarations and certifications, with the aim of developing at least 28 new ones, and we will further develop our Door Efficiency Calculator to meet our customers’ needs. Of course, we will continue to pilot product take-back solutions in several markets, including Germany, Switzerland, and the UK.
In terms of Material Compliance, we will implement a compliance and supplier engagement process in Germany to gain more information from our suppliers on hazardous materials and supply chain due diligence for materials in our products.
Another focal point will be to continue developing sustainable packaging concepts – particularly for specific products that are popular in Scandinavia, where the demand for such concepts is very high.