Sandals Has Greatly Increased Over Recent Years, While Attention to Environmental Impact Has Been Ignored

Home , Sandal, Shoe

The Sport Sandal…

LCA of (Re)Tire-d Soles

Laura Weyl, Ben Koons, Swetha Sampathgiri, and Nandan Shetty ENGS 171 S08 Contents

Problem Statement

Manufacturing LCA of Chaco

Tire Waste

Manufacturing LCA of the (Re)-tire-d Sole

Crumb Rubber

Transportation

Lifetime

End Life

Results and Conclusions

Citations

Appendix

1 Problem Statement

The market for sport sandals has greatly increased over recent years, while attention to environmental impact has been ignored. With 189 kTons of virgin rubber used each year, we believe there is potential for redesign that will greatly improve the environmental impact of the sport sandal by using recycled rubber tires.

Manufacturing LCA of Chaco

Chaco sandals are made from four major components, which can be broken down into materials and processes. There is the shoe bed, made up of synthetic rubber and polyurethane, which makes up the majority of each 29 oz. shoe. There is a single strap made of polyester webbing and finally a small plastic buckle. In order to make and assemble each sandal, materials must be extracted and synthesized into rubber and then molded to the shape of the shoe bed. The polyurethane is chemically produced and stamped, which happens in China before being shipped to the US. The polyester webbing is manufactured in France and then shipped to the US for cutting and assembly. In Colorado, the sole is trimmed and the webbing is sewn to the foot bed and woven through the shoe using textile machining and manual assembly.

Rubber Manufacturing Energy Usage (MJ per pair of chacos)

1% 7% 10% 3%

12%

Electricity

Coal

Na tur a l G a s

Distillate

JetFuel

Residual 67%

Rubber manufacturing Energy Usage

Each process, starting with the synthetic rubber manufacturing, was carefully dissected and considered for energy use, emissions, and toxic releases for a variety of categories. The results can be seen in Appendix I. The data has been approximately calculated for a single pair of Chaco sandals men’s size 9 (considered to be average weight and most popular shoe sold) using the Carnegie Mellon University website.

2 Rubber manufacturing uses about 18.7 MJ of energy, creates about 0.144 oz. of CO emissions, and releases about 1.54 grams of toxic waste into the land and water streams. Polyurethane manufacturing utilizes 44 MJ of energy, creates about 0.5 oz. of CO emissions, and releases as much as 3.3 grams of toxins into to water and land systems. Polyester manufacturing uses 8 MJ of energy, creates as little as 0.08 oz. of CO emissions, and releases 0.85 grams of toxins per pair of Chaco sandals. Finally, textile machining uses about 2.3 MJ of energy, creates less than 0.06 oz. of CO emissions, and releases 0.35 grams of toxins. Though there are numerous ways to improve the life cycle environmental impact of sandal production, the focus of the remainder of this project will be on eliminating and reducing the embodied energy of sandal production. The embodied energy in manufacturing appears to be more influential than the emissions and toxic releases. It is made up of nearly 50% Natural Gas consumption, followed closely by coal burning, and production of electricity making up the next 25% of the embodied energy in Chaco manufacturing. The total energy usage for a pair of Chaco sandals is 73.3 MJ, 79.4 TJ a year!

Tire Waste

Used tire disposal is a huge problem all over the world. In the US alone there are over 290,000,000 tires disposed of each year. Although they have a high energy and material value most end up in a landfill or are illegally dumped. They then become breeding grounds for mosquitoes and rodents. Although tires are not considered hazardous waste by the EPA they still pose serious environmental risks. They are a high fire hazard when stores together. When burnt they release toxic gas, heavy metals and oil. There is 55,000 gallons of oil run off for every million tires burned.

To reduce the environmental impact of used tires and recapture some of their value there has been a recent increase in the market for post consumer tires. They are used for a variety of applications including: noise barriers, artificial reefs, fuel, Earthship houses, road paving mix, sports surfaces, roofing, solid rubber wheels, shoes and more.

Manufacturing LCA of the (Re)-tire-d Sole

The concept behind the (Re)-tire-d Sole is to utilize existing rubber from recycled vehicle tires rather than using virgin rubber, therefore cutting out the entire rubber manufacturing process from the Life Cycle Analysis of our new shoes. The (Re)-tire-d Sole has three main components, all made from recycled rubber. First, the shoe sole cut or stamped out of recycled tires. Next, the crumb rubber shoe base is added for comfort and durability, and finally, there will be a rubber strap. The three components will all be connected using a shoe adhesive. The overall shoe will weigh about 600 grams when manufacturing and assembly is complete.

3 Recycled tires are retrieved and shipped to factory locations from within the United States before being cut, churned, and assembled into (Re)-tire-d Soles. The environmental footprint due to the shipping is addressed in the section devoted to transportation. We would suggest that each manufacturing site employ manual laborers to cut the tires for the shoe soles, therefore employing more American citizens and boosting the local economy. The direct environmental impact of this would be negligible. In order to save money and possibly be more profitable in the long run, machinery could be purchased to automate the stamping of the rubber into the forms of straps and shoe soles. The energy use to stamp a single pair of (Re)-tire-d Soles is 6.9 MJ. The associated CO emissions are about 5.9 grams per pair of shoes, and the total associated toxic releases for land and water are 1.5 grams. Clearly the addition of this automated process increases the overall environmental impact of the (Re)-tire-d Sole significantly.

Energy Use from Rubber Stamping 2%

7% 18% 3% Elec (MkWh) 2% Coal NatGas

LPG MotGas Distillate 22% Kero Jetfuel 44% Residual

Rubber Stamping Energy Use

The second major factor in manufacturing the (Re)-tire-d Sole is the adhesive used to connect the strap to the sole and the sole to the crumb rubber shoe base, as well as the adhesive used to hold the crumb rubber in place. The use of adhesives in shoes is very common and difficult to avoid. The energy used to make the adhesive is as high as 1.2 MJ per pair of shoes. The associated CO emissions are about 0.9 grams per pair of shoes, and the total associated toxic releases for land and water are 0.12 grams, see Appendix 2 for more detailed data.

4 In summary, assuming that the (Re)-tire-d Sole replaces Chaco sales making 520,000 shoes each year, manufacturing will utilize 4.9 TJ of energy every year, it will create 3,558 kg of CO each year and release 663.2 kg of toxins into the surrounding land and waterways. Though these numbers appear large and of course are not ideal, they are significantly lower than the 79 TJ of energy used to manufacture Chacos each year.

Crumb Rubber

Crumb Rubber consists of shredded tire particles ranging from about 5mm to 1 mm. The most common method for shredding is the crackermill process that tears apart the tire using corrugated steel drums. It takes 1.84 MJ/kg of energy to shred tires with this method, leading to .55 MJ/ pair of sandals totally .285 TJ per year. Other methods, such as granulation and micro-milling, are also used and require similar infrastructure and energy. Looking more closely at the energy breakdown it turns out that only about 5% of the total energy in used for the shredding process and the rest is used for transportation. To reduce the transportation component it makes sense to decentralize the shredding process with more smaller, and potentially portable, shredders. It is safe to assume that decentralization could reduce the transportation impacts by up to 25% and would potentially increase the shredding energy by a factor of two due to the smaller size. This results in an energy use of .65 MJ/kg or .102 TJ/year, a reduction by almost a factor of 3. Packaging

Chaco packaging uses close to 100% recycled content, broken down into two different types: recycled corrugated cardboard boxes with tissue paper, as well as biodegradable corn polymer bags. The greatest environmental impact occurs with the cardboard box packaging method.

Corrugated fiberboard consists of one inner layer of pleated paperboard sandwiched between and glued with starched based adhesives to two flat pieces of kraft paper with a typical density of approximately 127 g/m2. Each box also contains 1ft2 of wrapping tissue paper. Paper production is an energy intensive process, and cardboard boxes are not environmentally friendly. Were Chaco to package only with cardboard boxes, packaging energy use would sum to 11.05 TJ/yr, toxic releases 2.88 MT/yr, and emissions 781.2MT/yr. This amount could be reduced by preferentially packaging with the biodegradable corn polymer bag method.

Chaco polymer bags are produced from Polylactic Acid (PLA) generated from cornstarch. PLA is both made from a renewable resource and is biodegradable, two fundamentals of sustainability. However, plant-based plastics are also associated with environmental issues. For example, the biological breakdown of plastics releases carbon dioxide and methane. In addition, creating plastic from plants has an enormous energy requirement. Fossil fuel energy also goes into producing pesticides, herbicides, and fertilizer for corn. While having less of an eco-footprint than cardboard boxes, in many

5 ways PLA bags have a much bigger environmental impact than conventional polyethylene plastic bags. While Chaco PLA plastic packaging would consume 1.74 TJ/yr, release .133MT/yr of toxic releases, and emit 243.3 MT/yr of greenhouse gases, polyethylene bags would total .23TJ/yr, .019MT/yr, and 17.8 MT/yr, respectively.

Given this disparity, one might question why PLA is to be preferred over polyethylene. One major consideration is that the major producer of PLA, Natureworks LLC, offsets all non-renewable energy with wind power renewable energy certificates, making them the 19th largest carbon offsetter in the country. Furthermore, the biodegradable plastic industry is very young compared to petro-chemical manufacturing. With time, energy efficiency will improve, and Natureworks has improved the energy efficiency of their PLA production every year, resulting in significant reductions in pollutants and energy consumed. Finally, PLA is currently produced from corn, an over subsidized agribusiness that is too energy intensive and uses more nitrogen fertilizer, herbicides, and insecticides than any other US crop. PLA could instead be produced from cellulosic biomass, grasses, wheats, beats, and potatoes, which would require less energy. The corn market surplus is the problem. PLA is not, and polyethylene, a non- renewable plastic manufactured from petroleum should not be favored.

The LCA of the (Re)Tire-d Sole should incorporate PLA polymer bags to be shipped to customers. However, less than 1% of Chaco sales are direct; almost all are retail. For retail sales, perhaps the bag could be avoided entirely. The (Re)Tire-d Sole sandals could be tied together with a string and shipped to the retailer in large bulk cardboard boxes. Despite the environmental gains with this approach, a customer might alternatively prefer that their new sandals arrive in a bag. The total environmental impact from packaging the (Re)Tire-d Sole using these two options is listed in the following table.

Large Boxes with PLA Only Large Boxes bags

Energy 3.09 TJ/yr 1.35 TJ/yr

Toxic Releases .48 MT/yr .35 MT/yr

Emissions 338.57 MT/yr 95.27 MT/yr

Transportation

Transportation of goods is a high energy consumption sector. With increasing globalization, goods are transported across the world by sea or air freight. The footwear industry in the US imported over 2.2billion pairs in the year 2007 mainly from China.

Chaco

Chaco ships all if its raw materials from China. Shipping is a relatively environment-friendly mode of transportation in terms of tons transported per trip or tons per gallon of fuel. They do not use air freight to transport any material.

The materials are assembled in Colorado and transported to 1799 dealers all over the US. All products are moved only using truck transport. Truck transport uses distillate, gasoline or diesel for fuel implying that the emissions are mainly CO2 and NOx.

Assumptions:

For our calculations, we have assumed an average distance of 1342miles which is an average transportation distance for retail stores. Shipping distance is considered from Shanghai to LA and fuel consumption calculated according to nautical miles. The average capacity of a cargo freighter is 9000 TEU (twenty-foot equivalent units) each of which can carry about 21.6 tons. All of the raw material from China was assumed to be transported in one trip and a fraction of the weight of the ships capacity was considered. Similarly, a fraction of the 18-wheeler truck transportation was considered which has an average capacity of 60tons.

Based on these assumptions, the energy for shipping from China was about 5600MJ/yr. Transportation within the US consumes more energy of over 309,500MJ/yr.

Local Manufacturing:

Energy utilization by transportation can be decreased significantly if manufacturing units are located close to the source of raw materials. Also, decentralized manufacturing at multiple manufacturing units can reduce transportation from manufacturing plant to warehouse and then to retail stores and instead can be shipped directly to the retail stores. There are over 3000 landfills in the US

Assumptions:

7 There are over 3000 landfills in the US and we assumed 10% of them would have tires being dumped in them. This gives us 300 manufacturing units across the US. If we consider a 100km radius these 300 would cover the area of USA. We then considered that each of these units sold to one retail outlet at an average distance of 50km.

According to these assumptions, the total transportation energy drastically reduces to 3000MJ/yr which is about 1% of the energy currently being consumed. See appendix III for a detailed analysis.

The impact of transportation can be reduced by locating manufacturing units close to the source of raw material. Increasing fuel efficiency of these trucks is also important. The impact of transportation can also be reduced by reducing the number of trips and increasing the number of sandals shipped on each trip. Also, using renewable energy or bio-fuels can reduce our dependence on fossil fuels.

Lifetime

Chaco Sandals have zero energy and resource use. They do, however have very slight material emission during use. Small amounts of the outer sole wear off and can potentially contaminate the environment. There have been several studies into the potential toxic effects of this sole residue from commercially available shoes. It turns out that tire rubber is much less toxic than standard footwear rubber and is much more abrasion resistant. This is primarily due to the fact that tires loose up to 20% of their mass while in use on the road, and therefore must be made from a fairly inert material. Also, the wear and tear of walking on a tire sole is significantly less than the wear the tire is designed for. The life time of a Chaco is about 2-3 years, although this varies considerably as they are generally not an individual’s primary footwear.

End Life

Although it is possible to resole Chaco sandals, the majority of them end up in the landfill. The materials are fairly inert so the main environmental end-of-life impacts are due to the transportation involved in disposal. The resoling involves similar transportation modes as the disposal so for the analysis it is safe to assume that all shoes, or each resoling, have the same transport related impact. Transport of disposed Chaco’s cost $80/ton which creates $16.7 TJ/ Million S, resulting in 1.7 MJ/pair. Assuming steady state in the sandal business, 520,000 Chaco’s are being disposed of annually, using .88 TJ/year.

Results and Conclusions

8 The sport sandal is a rapidly growing market that targets an active, and environmentally conscious user group and despite manufacturers awareness of environmental impact, there is room for improvement. Over 189 kTons of virgin rubber are used to make sport sandals each year, while 244,890 tons of rubber is sent to landfills in the form of vehicle tires each year. This proposal outlines the manufacturing redesign of the sport sandal to maintain comfort and durability while decreasing the environmental footprint of each and every shoe. The (Re)Tire-d Sole uses 100% recycled rubber and the only virgin material used in any part of the shoes is the adhesive. Transportation is kept to a minimum by having multiple manufacturing sites around the country and utilizing a vehicle that creates the crumb rubber while transporting the tires to factories. Packaging costs are also minimized by eliminating the individual box used for each pair of shoes with a simple tie connection.

Overall we find that if the (Re)Tire-d Sole were to replace the 520,000 pairs of shoes made by Chaco each year, 79 TJ of energy would be conserved and CO emissions would decrease by 3,251 Tons. The many assumptions made to calculate these results were “worst case scenarios,” therefore in reality the savings may be even greater than estimated. Chaco is the leader in environmental awareness among sport sandals today, therefore decreasing the number of other sport sandals manufactured would only increase the above stated savings. We also assumed every shoe to be the size of a Men’s size 9, which is unrealistic; many of the shoes would use less material and weigh less during transportation. We feel confident proposing the (Re)Tire-d Sole design for the new and improved sport sandal for its large environmental savings and positive social impact.

9 Citations http://www.epa.gov/epaoswer/non-hw/muncpl/tires/basic.htm http://thenumbersguru.com/2006/07/26/tires-in-the-united-states/ http://www.esupplystore.com/Brown-Corrugated-Boxes_c_67.html http://en.wikiversity.org/wiki/DFE2008_Grocery_Bags http://www.natureworksllc.com/our-values-and-views/life-cycle- assessment/~/media/Our%20Values%20and%20Views/LifeCycleAssesment/Basic_LCA/NTR_C ompleteLCA_1102%20pdf.aspx

Shades of Green. Popular Science, September 2007

How Green are Green Plastics? Gerngross, Tillman and Steven Slater. Scientific American, August 2000 http://www.scribd.com/doc/518871/Corrugated-Fiber-Board-Boxes http://www.articlesalley.com/article.detail.php/18210/160/Fashion-Style/Shopping-and-Product- Reviews/21/Choosing_Footwear_-_Why_Choose_Sandals

Charting the Course: Marine fuel efficiency and Emissions Conference, 2005 http://www.the-infoshop.com/study/pf36793-footwear.html http://www.fdra.org/Statistic%20Charts/stats.html http://www.sginews.com/sginews/gifs/SGI_rugfw_2003.pdf http://www.researchwikis.com/Footwear_Market_Research http://www.apparelandfootwear.org/Statistics.asp http://en.wikipedia.org/wiki/Containerization http://en.wikipedia.org/wiki/Container_ship http://www.epa.gov/garbage/tires/basic.htm http://www.rma.org/scrap_tires/scrap_tire_markets/scrap_tire_characteristics/#anchor135840 http://www.newsfactor.com/perl/story/16721.html http://p2library.nfesc.navy.mil/P2_Opportunity_Handbook/7_I_A_10.html http://www.bitre.gov.au/publications/33/Files/WP004.pdf http://www.epa.gov/epaoswer/non-hw/muncpl/landfill/tab_1.pdf

10 11 Appendix

Appendix I- Rubber Manufacturing

Rubber Manufacturing Energy Usage (MJ per pair of chacos)

1% 7% 10% 3%

12%

Electricity

Coal

Na tur a l G a s

Distillate

JetFuel

Residual 67%

Energy Total (TJ) Elec (MkWhCoal NatGasDistillat JetFuel Residual Total 26.60 0.72 3.25 17.50 0.75 0.17 1.86 Synthetic Rubber Manufacturing 14.20 0.32 0.00 11.40 0.03 0.00 1.56 Power generation and Supply 3.57 0.00 2.83 0.63 0.00 0.00 0.11 Petroleum Refineries 1.77 0.03 0.00 0.86 0.01 0.17 0.06 Pertochemical Manufacturing 1.49 0.03 0.00 1.35 0.00 0.00 0.01 Other chemical Manufacturing 1.08 0.07 0.17 0.77 0.00 0.00 0.01

MJ/pair Total 18.69 1.81 2.28 12.29 0.53 0.12 1.31 Synthetic Rubber Manufacturing 9.98 0.80 0.00 8.01 0.02 0.00 1.10 Power generation and Supply 2.51 0.00 1.99 0.44 0.00 0.00 0.08 Petroleum Refineries 1.24 0.08 0.00 0.60 0.00 0.12 0.04 Pertochemical Manufacturing 1.05 0.08 0.00 0.95 0.00 0.00 0.00 Other chemical Manufacturing 0.76 0.17 0.12 0.54 0.00 0.00 0.01

12 Rubber Manufacturing Emissions (ounces/pair of chacos)

0% 2%

16% 20%

SO2 CO 16% NOx VOC Lead 46% PM10

Emissions SO2 (mt) CO Nox VOC Lead PM10 Total 2.500 5.830 1.970 2.070 0.000 0.317 Power generation and Supply 1.630 0.081 0.739 0.007 0.000 0.035 Pertochemical Manufacturing 0.282 0.090 0.212 0.671 0.000 0.016 Petroleum Refineries 0.155 0.090 0.035 0.124 0.000 0.016 Oil and Gas extraction 0.111 0.189 0.083 0.127 0.000 0.004 Other chemical Manufacturing 0.065 0.007 0.004 0.004 0.000 0.004

Ounces/pair Total 0.062 0.144 0.049 0.051 0.000 0.008 Power generation and Supply 0.040 0.002 0.018 0.000 0.000 0.001 Pertochemical Manufacturing 0.007 0.002 0.005 0.017 0.000 0.000 Petroleum Refineries 0.004 0.002 0.001 0.003 0.000 0.000 Oil and Gas extraction 0.003 0.005 0.002 0.003 0.000 0.000 Other chemical Manufacturing 0.002 0.000 0.000 0.000 0.000 0.000

13 Rubber Manufacturing Toxic Releases (grams per pair of chacos)

Non-Point 3% 10% Point 13% Total Air 37% Water 24% Land Underground 5% 6% 2% Total POTW

Non-Point Toxins Point TotAir Water Land U'ground Total POTW (kg) Total 612.00 809.00 1420.00 114.00 362.00 297.00 2190.00 164.00 Synthetic Rubber Manufacturing 541.00 618.00 1160.00 43.40 2.64 113.00 1320.00 10.60 Petrochemical Manufacturing 23.20 32.40 55.60 23.00 1.31 78.70 159.00 64.20 Other chemical Manufacturing 19.30 32.80 52.10 19.50 1.13 55.60 128.00 44.40 Petroleum Refineries 8.07 12.10 20.20 7.64 0.41 0.96 29.20 1.52 Plastid and Resin Manufacturing 5.16 11.20 16.30 1.22 0.07 5.96 23.60 9.71 Grams/pair

Total 0.430 0.568 0.998 0.080 0.254 0.209 1.539 0.115 Synthetic Rubber Manufacturing 0.380 0.434 0.815 0.030 0.002 0.079 0.927 0.007 Petrochemical Manufacturing 0.016 0.023 0.039 0.016 0.001 0.055 0.112 0.045 Other chemical Manufacturing 0.014 0.023 0.037 0.014 0.001 0.039 0.090 0.031 Petroleum Refineries 0.006 0.009 0.014 0.005 0.000 0.001 0.021 0.001 Plastid and Resin Manufacturing 0.004 0.008 0.011 0.001 0.000 0.004 0.017 0.007

14 Polyurethane Manufacturing Energy Usage (MJ per pair of Chacos)

0% 2% 2% 4% 1%

13% 6% Electricity Coal 17% Natural Gas LPG MotGas Distillate 55% Kero Jetfuel Residual

Energy TJ Total Elec (MkWhCoal NatGas LPG MotGas DistillateKero Jetfuel Residual Total 22.700 0.899 4.270 13.800 1.640 0.412 0.935 0.000 0.207 0.416 Plastic Material and Resin Manuf 7.880 0.431 0.507 6.360 0.367 0.093 0.028 0.000 0.000 0.049 Power Generation and Supply 4.090 0.000 3.240 0.725 0.000 0.000 0.000 0.000 0.000 0.124 Petroleum Refineries 2.000 0.037 0.000 0.967 0.903 0.007 0.006 0.000 0.000 0.071 Petrochemical Manufacturing 1.730 0.037 0.000 1.560 0.097 0.018 0.005 0.000 0.000 0.006 Other Chemical Manufacturing 1.610 0.101 0.254 1.140 0.071 0.013 0.003 0.000 0.000 0.013

MJ/pair Total 44.038 6.279 8.284 26.772 3.182 0.799 1.814 0.000 0.402 0.807 Plastic Material and Resin Manuf 15.287 3.010 0.984 12.338 0.712 0.180 0.054 0.000 0.000 0.095 Power Generation and Supply 7.935 0.000 6.286 1.407 0.000 0.000 0.000 0.000 0.000 0.241 Petroleum Refineries 3.880 0.258 0.000 1.876 1.752 0.014 0.012 0.000 0.000 0.138 Petrochemical Manufacturing 3.356 0.258 0.000 3.026 0.188 0.035 0.010 0.000 0.000 0.012 Other Chemical Manufacturing 3.123 0.705 0.493 2.212 0.138 0.025 0.006 0.000 0.000 0.025

Polyerethane Manufacturing Emissions (ounces per pair of chacos)

0% 3% SO2

16% CO 27% NOx

VOC 13% 41% Lead

PM10

15 Emissions Metric Tons SO2 CO Nox VOC Lead PM10 Total 2.94 7.56 2.45 5.01 0 0.468 Power Generation and Supply 1.87 0.092 0.845 0.008 0 0.04 Petrochemical Manufacturing 0.327 0.105 0.246 0.777 0 0.018 Petroleum Refineries 0.175 0.101 0.039 0.14 0 0.018 Oil and Gas Extraction 0.142 0.241 0.106 0.162 0 0.005 Other Chemical Manufacturing 0.067 0.007 0.005 0.004 0 0.004

Ounces/pair Total 0.197 0.507 0.164 0.336 0.000 0.031 Power Generation and Supply 0.125 0.006 0.057 0.001 0.000 0.003 Petrochemical Manufacturing 0.022 0.007 0.016 0.052 0.000 0.001 Petroleum Refineries 0.012 0.007 0.003 0.009 0.000 0.001 Oil and Gas Extraction 0.010 0.016 0.007 0.011 0.000 0.000 Other Chemical Manufacturing 0.004 0.000 0.000 0.000 0.000 0.000

Polyurethane Manufacturing Toxic Emissions (grams per pair of Chacos) Non-Point Air (kg) Point Air 3% Tot Air Releases 7% Water Releases 33% 11% 2% Land Releases 7% U'ground Releases 24% Total Releases 2% 5% POTW Transfers 6% Offsite Transfers Total Rel/Trans

U'groun Non- Tot Air Water Land Total POTW Offsite Total d Toxins Point Point Air Release Release Release Release Transfe Transfer Rel/Tra Release Air (kg) s s s s rs s ns s Total 215 517 732 118 455 377 1680 422 146 2250 Plastic Material and Resin Manuf 127 275 402 30 1.62 146 580 239 35.2 853 Other Chemical Manufacturing 28.6 48.7 77.4 29 1.67 82.6 191 65.9 24.5 281 Petrochemical Manufacturing 26.9 37.5 64.4 26.6 1.52 91.1 184 74.4 28.2 286 Petroleum Refineries 9.09 13.6 22.7 8.61 0.463 1.08 32.9 1.71 1.73 36.3 Other basic Inorganic Chemical M 5.03 17.1 22.1 6.93 13.9 19.9 62.8 10.9 8.26 82

Grams/Pair Total 0.417 1.003 1.420 0.229 0.883 0.731 3.259 0.819 0.283 4.365 Plastic Material and Resin Manuf 0.246 0.534 0.780 0.058 0.003 0.283 1.125 0.464 0.068 1.655 Other Chemical Manufacturing 0.055 0.094 0.150 0.056 0.003 0.160 0.371 0.128 0.048 0.545 Petrochemical Manufacturing 0.052 0.073 0.125 0.052 0.003 0.177 0.357 0.144 0.055 0.555 Petroleum Refineries 0.018 0.026 0.044 0.017 0.001 0.002 0.064 0.003 0.003 0.070 Other basic Inorganic Chemical M 0.010 0.033 0.043 0.013 0.027 0.039 0.122 0.021 0.016 0.159

16 Polyester Manufacturing Energy Usage (MJ per pair of Chacos) 3% 0% 1% 1% 4% Electric 5% 14% Coal NatGas 23% LPG MotGas Distillate 49% Kero Jetfuel Residual

Energy TJ Total ElectricCoal NatGas LPG MotGas Distillate Kero Jetfuel Residual Total 22.90 0.96 5.74 12.30 1.06 0.38 0.87 0.00 0.18 1.36 Noncellulosic organic fiber manufa 10.70 0.57 1.80 6.68 0.41 0.11 0.04 0.00 0.00 1.05 Power generation and supply 4.26 0.00 3.37 0.75 0.00 0.00 0.00 0.00 0.00 0.13 Other basic organic chemical manu 1.71 0.11 0.27 1.22 0.08 0.01 0.00 0.00 0.00 0.01 Petroleum refineries 0.75 0.01 0.00 0.36 0.34 0.00 0.00 0.00 0.00 0.03 Plastics material and resin manufa 0.68 0.04 0.04 0.55 0.03 0.01 0.00 0.00 0.00 0.00

MJ/pair Total 8.04 1.21 2.02 4.32 0.37 0.13 0.31 0.00 0.06 0.48 Noncellulosic organic fiber manufa 3.76 0.72 0.63 2.35 0.14 0.04 0.01 0.00 0.00 0.37 Power generation and supply 1.50 0.00 1.18 0.26 0.00 0.00 0.00 0.00 0.00 0.05 Other basic organic chemical manu 0.60 0.14 0.09 0.43 0.03 0.00 0.00 0.00 0.00 0.00 Petroleum refineries 0.26 0.02 0.00 0.13 0.12 0.00 0.00 0.00 0.00 0.01 Plastics material and resin manufa 0.24 0.05 0.02 0.19 0.01 0.00 0.00 0.00 0.00 0.00

17 Polyester Manufacturing Emissions (ounces per pair of Chacos) 0% 2% SO2 14% 19% CO 16% NOx 49% VOC

Lead

Emissions SO2 CO NOx VOC Lead PM10 Total 2.48 6.42 2.06 1.84 0 0.326 Power generation and supply 1.95 0.096 0.88 0.009 0 0.041 Petrochemical manufacturing 0.104 0.033 0.078 0.246 0 0.006 Petroleum refineries 0.066 0.038 0.015 0.053 0 0.007 Oil and gas extraction 0.062 0.106 0.046 0.071 0 0.002 Ot he r basic inorg anic chemical ma 0.036 0.004 0.002 0.002 0 0.002

Ou n c es/p ai r Total 0.03073 0.08 0.02552 0.0228 0 0.004 Power generation and supply 0.0241 6 0.001 0.0109 0.00011 0 0.0005 Petrochemical manufacturing 0.0012 9 4 E-04 0.00097 0.00305 0 7E-05 Petroleum refineries 0.0008 2 5 E-04 0.00019 0.00066 0 9E-05 Oil and gas extraction 0.0007 7 0.001 0.00057 0.00088 0 2E-05 Ot he r basic inorg anic chemical ma 0.0004 5 5 E-05 2.5E-05 2.5E-05 0 2E-05

Polyester Manufacturing Toxic Releases (grams per pair of Chacos)

Non-Point Air (kg) 4% Point Air 1% 6% 2% Tot Air Releases 4% 32% Water Releases 18% Land Releases U'ground Releases 30% Total Releases 1% POTW Transfers Offsite Transfers 2% Total Rel/Trans

18 Non- Point Tot Air Water Land U'ground Total POTW Offsite Total Toxins Point Air Air Releases Releases Releases Releases Releases Transfers Transfers Rel/Trans (kg) Total 103.0 360.0 462.0 128.0 313.0 1510.0 2420.0 151.0 84.4 2650.0 Noncellulosic organic fiber manufa 30.6 115.0 146.0 65.9 1.9 1350.0 1560.0 5.5 5.8 1580.0 Other basic organic chemical manu 30.5 51.8 82.2 30.8 1.8 87.8 203.0 70.1 26.0 299.0 Plastics material and resin manufa 10.9 23.6 34.5 2.6 0.1 12.6 49.8 20.5 3.0 73.4 Petrochemical manufacturing 8.5 11.9 20.4 8.4 0.5 28.9 58.2 23.6 8.9 90.7 Petroleum refineries 3.4 5.1 8.6 3.2 0.2 0.4 12.4 0.6 0.7 13.7

Grams/pair Total 0.036 0.126 0.162 0.045 0.110 0.530 0.850 0.053 0.030 0.931 Noncellulosic organic fiber manufa 0.011 0.040 0.051 0.023 0.001 0.474 0.548 0.002 0.002 0.555 Other basic organic chemical manu 0.011 0.018 0.029 0.011 0.001 0.031 0.071 0.025 0.009 0.105 Plastics material and resin manufa 0.004 0.008 0.012 0.001 0.000 0.004 0.017 0.007 0.001 0.026 Petrochemical manufacturing 0.003 0.004 0.007 0.003 0.000 0.010 0.020 0.008 0.003 0.032 Petroleum refineries 0.001 0.002 0.003 0.001 0.000 0.000 0.004 0.000 0.000 0.005

Appendix II: Manufacturing LCA of the (Re)‐tire‐d Sole

Rubber Stamping Energy Use:

Energy Use from Rubber Stamping 2%

7% 18% 3% Elec (MkWh) 2% Coal NatGas

LPG MotGas Distillate 22% Kero Jetfuel 44% Residual

MJ/pair Total Elec (MkWh) Coal NatGas LPG MotGas Distillate Kero Jetfuel Residual Total for all sectors 6.948 1.451686047 1.7563 3.4845 0.1468 0.23253 0.561313 0 0.1208 0.19249 Power generation and supply 1.974 0 1.5666 0.34985 0 0 0 0 0 0.059714 Adhesive manufacturing 1.581 0.280726744 0.0745 1.34884 0.0035 0.01124 0.009133 0 0 0.051284 Other basic inorganic chemical m 1.012 0.422354651 0 0.76575 0.0281 0.05901 0.017563 0 0 0.011943 Petroleum refineries 0.275 0.00252907 0 0.00562 0.0007 0.04004 0.228319 0 0 0 Other basic organic chemical man 0.105 0.022761628 0.0267 0.05409 0.0007 0.0007 0.000703 0 0 0.014753

Rubber Stamping Emissions:

Emissions from Rubber Stamping

0% 14% 8%

SO2 12% CO

Nox

VOC

Lead

PM10

61%

grams/pair SO2 CO Nox VOC Lead PM10 Total 1.36289 5.90818797 1.166182 0.723595 0.00281 0.44048 Adhesive manufacturing 0.90625 0.04496124 0.408164 0.0042151 0 0.018968 Power generation and supply 0.14331 1.21535852 0.112403 0.0681444 0.000703 0.10046 Other basic inorganic chemical m 0.07095 0.00210756 0 0.0035126 0 0.007728 Petroleum refineries 0.0562 0.3119186 0 0.0028101 0 0.01405 Petrochemical manufacturing 0.04988 0 0.011943 0.0112403 0 0.004918

Rubber Stamping Toxic Releases:

20 Toxic Releases from Rubber Stamping

1% Non-Point Air (kg) 3% Point Air 4% Tot Air Releases 1% 33% Water Releases 22% Land Releases

U'ground Releases 1% 6% Total Releases

1% 28% POTW Transfers Offsite Transfers

Total Rel/Trans

U'groun Non- Land POTW Offsite Total Tot Air Water d Total Point Air Point Air Release Transfer Transfer Rel/Tran Releases Releases Release Releases (kg) s s s s Grams/Pair s Total for all sectors 0.037234 0.120131 0.157364 0.062384 0.92733 0.02585 1.173207 0.05311 0.239559 1.468266 Adhesive manufacturing 0.015947 0.026625 0.042573 0.00044 7.5E-05 0 0.043064 0.02311 0.022621 0.088517 Synthetic rubber manufacturing 0.00347 0.003239 0.006702 0.043697 0.02908 0.00047 0.080087 0.00115 0.147529 0.228319 Other basic organic chemical man 0.002585 0.000557 0.003147 0.000617 0.00941 0 0.013207 4.2E-06 0.00104 0.014261 Plastics material and resin manuf 0.001714 0.005353 0.007095 3.09E-05 0.00062 0 0.007728 0 0.001553 0.009273 Other basic inorganic chemical m 0.000836 0.001419 0.002255 0.000843 4.8E-05 0.00241 0.005557 0.00192 0.000717 0.008219

Adhesive Manufacturing Energy Use:

21 MJ/pair Total Elec (MkWh) Coal NatGas LPG MotGas Distillate Kero Jetfuel Residual Total for all sectors 1.3432 0.1977264 0.272 0.6992 0.0801 0.0441 0.09476 0 0.0165 0.07498 Power generation and supply 0.2714 0 0.215 0.04812 0 0 0 0 0 0.008188 Adhesive manufacturing 0.2622 0.043056 0 0.18216 0.0107 0.0143 0.001656 0 0 0.040664 Other basic inorganic chemical 0.1049 0.0337824 0 0.08823 0.0052 0.0009 0.000276 0 0 0.000276 Petroleum refineries 0.0915 0.0059616 0 0.04434 0.0414 0.0003 0.000276 0 0 0.003312 Other basic organic chemical m 0.0811 0.018216 0.013 0.05759 0.0036 0.0006 0.000184 0 0 0.000644

Energy Use in Shoe Adhesive Manufacturing and Use 5% 1%

0% 6% 13% Elec (MkWh) 3% Coal 5% NatGas 19% LPG

MotGas

Distillate

Kero

Jetfuel

Residual 48%

Adhesive Manufacturing and Use Emissions:

22 Total Emissions of Shoe Adhesive Manufacturing and Use

29% SO2

18% CO

Nox

VOC

Lead

PM10

41%

grams/pair SO2 CO Nox VOC Lead PM10 Total 0.6523 0.920015477 0.394 0.1932 0 0.0659 Adhesive manufacturing 0.4683 0.128802167 0.216 0.01794 0 0.0326 Power generation and supply 0.1242 0.006164104 0.056 0.00055 0 0.0027 Other basic inorganic chemical 0.0095 0.001012017 6E-04 0.00055 0 0.0006 Petroleum refineries 0.008 0.004692079 0.002 0.00644 0 0.0008 Petrochemical manufacturing 0.007 0.002208037 0.005 0.01665 0 0.0004

Adhesive Manufacturing and Use Toxic Releases:

Toxic Releases in Shoe Adhesive Manufacturing and Use Non-Point Air (kg) Point Air 3% Tot Air Releases 7% Water Releases 10% 33% Land Releases 1% U'ground Releases 12% Total Releases 2% 3% POTW Transfers 3% 26% Offsite Transfers Total Rel/Trans

23 Non- Tot Air POTW Offsite Water Land U'ground Total Total Point Air Point Air Release Transfer Transfer Releases Releases Releases Releases Rel/Trans Grams/Pair (kg) s s s Total for all sectors 0.01104 0.026956 0.038 0.005216 0.046368 0.012788 0.10212 0.011684 0.00887 0.12328 Adhesive manufacturing 0.003873 0.006955 0.01086 3.9E-05 4.38E-05 0 0.010948 0.000795 0.00139 0.013064 Synthetic rubber manufacturing 0.001481 0.001684 0.00316 0.000119 7.27E-06 0.000308 0.003597 2.91E-05 5.5E-05 0.00368 Other basic organic chemical m 0.001444 0.002456 0.0039 0.001463 8.43E-05 0.004158 0.009568 0.003321 0.00123 0.014168 Plastics material and resin man 0.000871 0.001886 0.00276 0.000206 1.11E-05 0.001003 0.003984 0.001638 0.00024 0.00586 Other basic inorganic chemical 0.00071 0.00241 0.00313 0.000975 0.001969 0.002806 0.008887 0.001536 0.00117 0.011592

Appendix III: Transportation

Chacos Shipping Emissions in MT/yr 0.000 0.000 0.012 0.000 0.001 0.000 Carbon dioxide Carbon monoxide Methane (CH4) Nitrogen oxides (NOx)

0.412 Particulates (PM10) Sulfur oxides (SOx) VOC

Chacos Truck Emissions in MT/yr 0.05 0.22 12.85 0.42 3.07 0.030.63 Carbon dioxide Carbon monoxide Methane (CH4) Nitrogen oxides (NOx) Particulates (PM10) 1928.56 Sulfur oxides (SOx) VOC

24 China Imports Shipping Emissions in MT/yr 0.001 0.006 Carbon dioxide Carbon monoxide Methane (CH4) Nitrogen oxides (NOx)

0.206 Particulates (PM10) Sulfur oxides (SOx) VOC

China Imports Truck EmissionsMT/yr

0.02 0.320.11 1.53 6.43 0.02 0.21 Carbon dioxide Carbon monoxide Methane (CH4) Nitrogen oxides (NOx) Nitrous oxide (N2O) 964.28 Particulates (PM10) Sulfur oxides (SOx) VOC

25 Local Emissions in MT/yr

0.01 3.75 0.12 0.900.01 0.06 0.19 Carbon dioxide Carbon monoxide Methane (CH4) Nitrogen oxides (NOx) Nitrous oxide (N2O) 563.16 Particulates (PM10) Sulfur oxides (SOx) VOC