Into the Wild Green Yonder — Our 4th Carbon Neutral DVD
Futurama, Twentieth Century Fox Television (TCFTV) and Twentieth Century Fox Home Entertainment (TCFHE) are committed to reducing our impact on climate change. Futurama: Into the Wild Green Yonder is the company’s fourth carbon-neutral DVD release. The previous three DVD carbon-neutral releases were the Futurama titles Bender’s Big Score, The Beast with a Billion Backs, and Bender’s Game. Bender’s Big Score, the company’s first-ever carbon neutral DVD, was awarded the most environmentally friendly DVD of the year by The Digital Entertainment Group at the inaugural Green Media Summit in Los Angeles.
Our strategy to reach net zero emissions for the DVD was three-fold:
- To measure our carbon impact
- To reduce our energy use and switch to renewable sources of power wherever possible and to encourage suppliers to reduce their climate impact
- To offset our unavoidable emissions
Measuring our carbon impact
To conduct this analysis, we worked with Clear Carbon Consulting and used the Greenhouse Gas Protocol, developed by the World Resources Institute and the World Business Council for Sustainable Development, to instruct our measurement methodology.
For manufacturing and distribution, we applied the findings of the Wal-Mart/Fox Home Entertainment case study that was published by the Carbon Disclosure Project in September 2007. That study measured the supply-chain impacts of a DVD defined as a single disc, packaged in a hard case that includes a lithograph sleeve, with one printed promotional leaflet inside the DVD case. In addition, we collected data on the Futurama production offices (both internal and outsourced) as well as the business air travel association with the DVD.
Here are the combined findings:
Reducing energy use, switching to renewables & encouraging suppliers
Several energy efficiency initiatives are underway at Futurama, TCFTV and TCFHE offices. These initiatives include lighting upgrades, maximization of chiller units, IT energy reductions, and other office equipment efficiencies.
The manufacturing facility for TCFHE DVDs is owned and operated by Cinram in Huntsville, AL. In recent years, Cinram has completed significant energy efficiency and waste reduction projects. Energy efficiencies include the installation of highly efficient electric injection molding technology and a highly efficient boiler, resulting in substantial electricity and natural gas savings.
With regards to waste reduction, Cinram has taken on recycling and reuse programs in its markets. All “waste” products are sorted at the Cinram facility in order to separate potential valuable elements for use by other industries and businesses within the community. As a result, Cinram has created partnerships with other companies in the area to take the “waste” for reuse in other products, resulting in the great majority (at least 98 percent) of the facility’s waste being reused rather than disposed of in landfills.
One of TCFHE’s printing suppliers completed significant energy efficiency upgrades over the past two years, resulting in reduced energy consumption by 750,000 kWh and more than 80,000 ccf of natural gas. Future initiatives include energy audits at supplier facilities, including Cinram, printers, case manufacturers, and raw material providers. Additionally, Futurama, TCFTV and TCFHE are seeking out new opportunities future carbon reductions and working with their partners to do the same.
Elements included in supply chain analysis:
Production – Includes electricity from production and animation offices and recording studio (all in California), as well as the overseas animation office in South Korea.
Outsourced production – Includes emissions associated with outsourcing of audio mixing, composing and sound design.
Business air travel – Includes all business air travel associated with production of the DVD.
Manufacture of Supplied Goods – Includes emissions associated with the following production components and emissions sources:Third-party creative design (purchased electricity), manufacturing of plastic DVD cases (purchased electricity, fuel combustion), printing of cover sheets and promotional inserts (purchased electricity, fuel combustion), manufacturing of polycarbonate raw material (purchased electricity, fuel combustion), manufacturing of silicon raw material (purchased electricity).
Transportation of Supplied Goods – Includes emissions from mobile fuel combustion associated with the transportation of supplied goods to the facility where DVDs are manufactured and packaged. Calculations were made on the basis of either ton mileage estimates or actual fuel consumption data for transportation of the following supplied goods: creative materials, plastic DVD cases, printed cover sheets/inserts, polycarbonate, silicon, aluminum, and corrugated cardboard.
Manufacture of Finished Goods – All of the manufacturing of TCFHE’s DVDs is outsourced to Cinram. Therefore, the emissions associated with the manufacturing process are described in the Outsourced Manufacture of Finished Goods category. In addition to traditional manufacturing, this category includes the emissions associated with the following production component sources: TCFHE film editing/mastering and in-house creative design (purchased electricity).
Outsourced Manufacture of Finished Goods – Includes emissions associated with the following production components and emissions sources: DVD manufacturing/packaging (purchased electricity, fuel combustion, refrigerants). These activities occur at the Cinram plant in Huntsville, Alabama.
Transportation to Market – Includes emissions from mobile fuel combustion associated with the transportation of finished DVDs to Wal-Mart Stores (note: that DVDs are a direct-to-store product, meaning that shipments are not routed through Wal-Mart’s distribution center network). This also includes emissions from transportation of returned product.