Design for Environment - Wharington 'Re-Define' Furniture

The 'Re-Define' furniture range is the outcome of a project to develop high-quality environmentally sustainable large furniture for the commercial market. The furniture was designed and prototyped by the team of Wharington International Pty Ltd, Centre for Design at Royal Melbourne Institute of Technology (RMIT), and MID Commercial Furniture following the receipt of a grant from EcoRecycle Victoria in July 1999. The motivation for the project was to develop a sophisticated furniture product with minimal environmental impact across the furniture life cycle - from materials selection and production through to distribution, use, reuse, recycling and ultimate disposal. This design for environment (DfE) approach was adopted to ensure that environmental problems were minimised, and that 'environmental' factors in general provided a source of innovation. The life cycle approach also helped to guard against problems addressed in one stage negatively affecting the environmental performance at another stage.

The project also marks a significant step towards demonstrating that DfE can deliver high-quality products demanded by designers, specifiers and facilities managers in the commercial fit-out industry. The need to blend eco-efficiency with striking aesthetic qualities was a high priority for the project team.

The team

Wharington International was established in 1889, with original products including homewares and office products, cash boxes, trunks, milk churns and bicycles. In the 1970s the business expanded into plastics, moulding resin chair shells to accompany its range of chair mechanisms, metal furniture frames and components produced in the engineering plant. Today Wharington has developed the technology to incorporate recycled resins into its Recopol^TM furniture shells. See http://www.wharington.com.au for more information.

The Centre for Design at RMIT University focuses on eco-efficiency as a source of innovation and responsible business development. It conducts a comprehensive program to promote and demonstrate the role of design and innovation in achieving a sustainable future for Australia. This involves interdisciplinary research, consulting, education, outreach and training. It is Australia's only research centre with an active, integrated and continuing program on leading-edge industrial environmental management tools, methods and processes related to:

Design-for-Environment and Sustainable Product Development;
Life Cycle Assessment (LCA) of products, processes, services and buildings;
Product Stewardship (often associated with extended producer responsibility)

See http://www.cfd.rmit.edu.au for more information.

MID Commercial Furniture is headed by Danish architect Torben Wahl, who was educated at the Royal Academy of Fine Arts in Copenhagen. The company is building expertise in the design of contemporary sustainable commercial furniture, a skill that is attracting significant interest and increased levels of customer demand. The company's future development will focus on achieving environmentally responsible products such as the 'Re-Define' furniture project.

The team approach was essential to ensure a high quality product with minimal environmental impact. The team combined the expertise of furniture design (MID Commercial Furniture), furniture production using post consumer resins (Wharington International), and expertise in DfE (Centre for Design at RMIT), with each organisation drawing on and learning from the skills of the other. This combination of skills has led to a prototype sofa and lounge chair, which at the time of writing is considered best practice in the furniture industry.

Design for environment

The major environmental impacts associated with commercial furniture occur during the manufacturing and disposal phases. Effects include:

Granulated recycled ABS resin

the use of toxic materials such as glues, solvents, dyes, paints and finishes that can cause serious health problems both during the manufacturing process and during the use of the furniture in indoor environments through off-gassing;
large amounts of timber waste from off-cuts, generated during the manufacturing stage;
greenhouse gas emissions related to steel and aluminium production;
the use of timbers such as rainforest species and scarce hardwoods that leads to the loss of forest ecosystems;
the use of plantation timbers from poorly managed areas resulting in habitat damage, soil erosion and water pollution;
the creation of solid waste through product turnover or 'churn', where the furniture loses its 'fashionability' due to colour, shape or finishes; and
the use of virgin synthetic materials that contribute to hazardous or toxic waste once deposited in landfill.

The process

The Centre for Design at RMIT prepared the design brief, and specified criteria to be met in regard to materials, manufacture, use, waste avoidance and resource recovery.

Example criteria from the design brief
Materials	minimise quantity of materials use materials void of any toxic or hazardous substances use metals with low embodied energy
Manufacture	reduce number of components and assemblies integrate functions and simplify assembly eliminate solvent based adhesives
Use	minor repairs should be straightforward use materials which contribute to healthy, vibrant and productive workplace through innovative use of colour, texture, surface design etc.
Waste avoidance and recovery	Extend product life through design for durability, reuse, refurbishment and materials recycling to keep furniture out of the solid waste stream, by: avoiding colours or designs that go out of fashion quickly; avoid glues, metal clamps and screws in favour of 'push, hook and click' assembly; and the use of in-mould labels rather than paper and plastic labels which can be mistakenly washed off or removed.

MID Commercial Furniture designed the 'Re-Define' range in accordance with the brief for use by their corporate, government and institutional clients. The team, led by the RMIT Centre for Design, undertook research on various components of the furniture to determine the best possible materials with regard to environmental benefit and cost.

Wharington International developed and moulded the Recopol^TM recycled resin furniture components using recycled acrylonitrite, butadiene and styrene (ABS) resin. ABS is an engineering-grade resin used for the casings and parts of home and office appliances such as vacuum cleaners, telephones, televisions, videos, computers, washing machines and refrigerators. A large majority of these disposed products presently go to landfill. The use
of these resins converts 'waste' into a quality product and provides a viable, cleaner replacement for forest plywoods, hardwoods, plantation timbers and virgin plastic for
internal framing in upholstered furniture.

RECOPOL^TM recycled ABS resin
The increasing cost of virgin ABS resin that began with the oil crisis of the 1970s prompted Wharington International to investigate the use of small amounts of less expensive recycled ABS resin in its furniture components. This action was initially to maintain a competitive edge for the moulded virgin resin shells over plywood shells for the furniture manufacturing industry, however, the method proved successful and the recycling industry responded with more material coming into the marketplace.

Wharington can now incorporate on average 75 per cent recycled resin into mouldings. The lower end of the recycled content scale is 25 per cent recycled resin if there is a high level of co-mingling with other resins, paper or metallic substances. A recycled rate of 100 per cent can be achieved with clean high single-grade materials, such as crushed telephones and vacuum cleaners.

When used for framing the recycled resin shell can be supplied at prices up to 30 per cent cheaper than conventional wooden framing. The resin shell also offers designers, manufacturers and specifiers the opportunity to create sustainable products that are pre-designed for production, lowering costs through a reduced number of components, minimising assembly time and reducing upholstery materials and labour costs.

A prototype of the 'Re-define' sofa and lounge chair have recently been completed with the following components:

Dunlop Enduro cut foam - the amount of foam to be used was minimised with the sofa's streamlined design and simplicity. The cutting method of the foam was also addressed to minimise waste. All scrap from foam cutting in general is sent for use in carpet underlays. Alternatives to foam were explored, including a latex product; however a suitable product could not be found to meet the strict specifications of the design brief.
Recopol^TM recycled resin internal shells - the resin shell was an important feature of the furniture due to the environmental benefits discussed previously.
Mild steel bearers - the steel is 100 per cent recyclable, and any scrap from the manufacturing process is collected for recycling.
Stainless steel legs - the steel is 100 per cent recyclable and does not require any toxic coatings or finishes.
Recycled PET fabric, or natural wool (to be decided) - both fabrics meet the design brief specifications.
Nylon feet - the nylon used is recyclable. Wharington is investigating the potential use of a recycled material for this component.
Other: Velcro, zips, nuts and bolts (mild steel and stainless steel) - all fastenings were designed to simplify the upholstery and enable easy removal for cleaning etc.

The prototype of the Re-Define Sofa

Issues and barriers

The issues and barriers related to recycled resin shells in general focus on finding an acceptance in the marketplace for their shells and persuading designers and furniture manufacturers to embrace a new sustainable material technology. The furniture manufacturing companies are reluctant to change from timber-based technology processes to utilising DfE principles in their manufacture. Despite low tooling costs, the manufacturers are reluctant to commit to recycled material shells and the use of professional designers, even when there is a tendency for commercial furniture design to be consistent, with only upholstery methods, finishes and fabrics changing from season to season.

Environmental benefits

Each Re-Define sofa and lounge chair will have the following environmental credentials:

Each Recopol^TM resin shell will contain the equivalent of approximately 45 post-consumer printer cases (approximately 39kg of waste material) that would otherwise have been sent to landfill.
The use of recycled materials reduces demand for forest products, conserving a natural resource and helping to preserve biodiversity.
The recycled resin shell will have been produced with 50 per cent less greenhouse gas emissions and 80 per cent less energy than a shell made with virgin ABS resin.
No toxic or hazardous materials (including solvents) will be used for the manufacture of the furniture or of its individual components.
The sofa has been designed to allow straightforward minor repairs with a durable fabric.
The Recopol^TM shell will be fully recyclable.
All stainless steel, steel and fabric used will be 100 per cent recyclable.
Wharington International will receive back used resin shells for remanufacture.

Economic benefits

The production of the 'Re-Define' furniture to meet the environmental design brief specifications has not proved to be any more expensive than previous pieces of quality furniture produced by Wharington International or designed by MID Commercial Furniture. Additional expenses have only been incurred in the design stage.

The furniture is currently in prototype form, and as such has not been released to the retail market, nor has a retail price been set for the sofa. The forecast payback period for the entire development of the 'Re-Define' commercial furniture range is one to two years based on previous sales records.

Financial comparisons between furniture production using a plywood frame and a resin shell are difficult to make due to the commercially sensitive nature of production costs. Wharington International has estimated that on average, a resin shell is about $30 to $40 more expensive to produce than a plywood frame. However, this does not account for labour costs (a plywood frame is a much more labour intensive process) or the costs associated with the remainder of the manufacturing process such as padding and upholstery, believed to be lower with a Recopol^TM resin shell.

Future

The 'Re-Define' furniture project will be documented in detail by the RMIT Centre for Design with a view to highlighting how DfE can be successfully applied in the Australian furniture sector. The project report will feature specific information and data about:

how the design brief was developed;
how priorities were established and how the DfE process came to life in practice;
how materials and components were sourced and evaluated;
the furniture's life cycle environmental performance;
Product stewardship planning for commercial furniture;
the role and value of strategic environmental marketing and alliances; and
contacts, tools and resources relevant to furniture design and manufacture.

Key sections of the project report will be transformed into a DfE guide for the furniture industry, published by EcoRecycle Victoria.

Contact information:

Yvette Karklins
Marketing Manager
Wharington International
48-50 Hargreaves Street
Huntingdale VIC 3166

Phone: 03 9544 5533
Fax: 03 9543 1907
Email: yvette@wharington.com.au
Internet: http://www.wharington.com.au

Case study prepared in September 2000

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Design for Environment - Wharington 'Re-Define' Furniture