Cables & wires Comprehensive CO₂ footprint for connectivity solutions published

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Scope 3 emissions, which occur along the entire value chain and often account for the largest share of a company's total CO₂ footprint, are rarely fully captured and published. Lapp aims to change this for its connectivity solutions.

Evaluating the climate compatibility of the products they purchase is becoming increasingly important for many companies. This not only enables sustainable purchasing and investment decisions but also helps to fulfill reporting obligations. The "Product Carbon Footprint" (PCF), i.e., the CO₂ footprint of a product, plays a central role in this. It encompasses the total amount of greenhouse gas emissions generated over a product's lifecycle and is an essential component of a company's sustainable commitment. However, its calculation is complex as it must consider factors such as complex supply chains, high data collection efforts, data gaps, and the quality of available information.

The cradle-to-gate approach includes the entire lifecycle of a product, from raw material extraction to leaving the logistics center, in the calculation of the CO2 footprint.

Lapp is one of the first companies in its industry to publish data on the CO₂ footprint of its products using the cradle-to-gate approach. This covers the entire lifecycle of a product, from raw material extraction to leaving the logistics center. To ensure data transparency and reliability, the data is verified by Dekra. The starting point is data for the popular Ölflex Classic 110 connection and control cable, with an additional 40 products from the Ölflex series to follow. In the future, the company also plans to extend its PCF analysis to its system products (Skintop, Skindicht) and data cables (Etherline, Unitronic).

Calculation according to ISO standard 14067

The basis for calculating the PCF is ISO standard 14067, which provides internationally recognized guidelines for quantifying a product's greenhouse gas emissions. The emissions are stated in the form of CO₂ equivalents (CO₂e), which consider not only CO₂ itself but also other greenhouse gases such as methane (CH₄) and nitrous oxide (N₂O). The first step involves a life cycle analysis. Since Lapp follows the cradle-to-gate approach, this analysis includes:

• Raw material extraction: Emissions from the extraction, processing, and transport of materials such as copper for the conductor and plastic for insulation and sheathing

• Production: Emissions during the manufacturing of the cable, including waste

• Transport, packaging, and storage: Emissions during transportation for the delivery of products between the production facility and the gate of the LAPP logistics center, as well as storage and packaging of the products

Ideally, primary data, which comes directly from the manufacturing companies and the involved suppliers, are collected. If primary data is not available, secondary data, such as averages from reliable databases like Ecoinvent, is used instead. In practice, the availability of primary data in sufficient quality is currently still very low, so generic data from the databases often has to be used. However, ISO 14067 requires that the data sources used are precisely documented and their quality assessed. Lapp is working on continuously improving data accuracy by intensifying dialogue with suppliers.

Use data for concrete actions

Anna Maier is Project Manager Product Sustainability at Lapp and is responsible for the PCF project within the company. She says: "Sustainability is part of Lapp's DNA. With the Product Carbon Footprint, we are creating transparency for a growing number of products, thus providing an important foundation for our overarching sustainability strategy." The data is intended not only to provide better information for Lapp, its customers, and partner companies but also to lead to concrete actions.

For example, copper used for the conductors of the cables accounts for over half of the emissions in the Ölflex series. Therefore, Lapp is considering relying on copper suppliers with a lower CO₂ footprint in the future, for instance, by using recycled copper. Lapp is also a partner of the quality assurance system "The Copper Mark," which ensures responsible copper production along the entire value chain.

Use renewable instead of fossil resources

Lapp is also working on biobased solutions for the compounds used in cables and connectors. They replace a certain proportion of fossil resources with renewable materials such as algae, corn, or agricultural waste, thus significantly improving the environmental and climate impact of the products. Lapp ensures that the plant-based raw materials do not compete with food production as far as possible. With the Etherline FD bioP Cat.5e data cable, the company has already launched the first series-produced cable with a biobased outer sheath on the market.

At SPS 2024, the company also presented prototypes for plugs and connectors, made from composite materials with a biobased content, which are close to market readiness. "With this, Lapp is showcasing new possibilities in the connectivity technology segment," says Anna Maier. "With our development of sustainable connection solutions, we are pioneering, participating in cross-market discussions, and are always in close exchange with our customers to ensure we keep their needs in mind not only in terms of sustainability but also quality and reliability."

Reduce energy losses during operation

In the future, Lapp will expand its approach beyond the cradle-to-gate area by including emissions and costs from the usage phase of a cable in the assessment—a factor that can significantly impact the overall balance. This holistic perspective provides crucial impetus for the further development and optimization of connectivity solutions.

A clear example of this is the cable cross-section: larger conductor cross-sections initially require higher investment and more material, but significantly reduce energy losses during operation. The result is considerably lower energy costs for customers and a significant reduction in greenhouse gas emissions. This advantage pays off over the entire lifecycle of a product.

With this comprehensive approach to collecting sustainability-related data, Lapp is setting new standards in the industry. Anna Maier explains: "We want to analyze our own impact on climate change—with the goal of reducing it. We are convinced that this foresight is a competitive advantage and also supports our customers and partners in achieving their sustainability and efficiency goals."