MML® - Innovating Sustainable Water Management in Tile Manufacturing
Malaysian Mosaics Sdn Bhd
“This project integrates with the company’s business goal to achieve sustainability and resilience in meeting increasing price competitiveness. By continuously driving green and lean manufacturing processes, this enables MML® to reduce costs without compromising its product and service quality.”
INTRODUCTIONWith a green legacy of over five decades, since its humble beginning MML® had already embraced an eco-compatible brand philosophy. Sustainability is part of the brand’s DNA, which has been consistently synergised across its 360° infrastructure throughout the MML® tile creation process.
Back when MML® was first established in a small town called Kluang, there was barely any infrastructure for water in the community. Innovative modifications were made to their factory roofs to harvest rainwater. Complemented with a simple recycling system, MML® was able to reuse the water for their manufacturing processes. From water conservation it became natural to extend a zero waste policy across all processes and materials. MML® brand’s aspiration is to be in the forefront of green initiatives in the ceramic tile industry. In line with the brand’s good corporate citizenship practice, the goal of this project is to reduce water consumption and prevent water pollution.
FRAMEWORK AND STRATEGYThrough the MML® zero discharge policy, 100% of its industrial effluent is treated via an industrial effluent treatment system (IETS). The treated water is then fully recycled in the MML® manufacturing process, optimising the utilisation of water resources for environmental sustainability.
This project integrates with the company’s business goal to achieve sustainability and resilience in meeting increasing price competitiveness. By continuously driving green and lean manufacturing processes, this enables MML® to reduce costs without compromising its product and service quality.
The scope of the project covers water resources, water recycling, water recovery and water reduction. Its multiple water resources encompass treated water from IETS, surface water and rainwater, which is recycled into the manufacturing process. Adopting the latest Dry Mono technology, MML® has also successfully eliminated the usage of water in its tile rectification and chamfering processes. The MML® water management system effectively reduces water consumption from Syarikat Air Johor (SAJ), conserving precious water resources.
ACHIEVEMENT AND IMPACTThrough the implementation of this project, MML® has successfully reduced water usage from SAJ. For the past three years, MML® has been able to sustainably derive 69% to 72% of its water requirements from its treated water, surface water and rainwater resources. This has contributed in cost savings to reduce manufacturing costs and meet increasing price competitiveness in the global market.
This project also contributes to environmental sustainability. With IETS, no waste water or treated water is discharged into public drains, reducing pollution to the water in the environment. By reducing water requirements from SAJ, the project has also aided in lessening the burden of water rationing within the community, and reducing chemical, electricity and sludge generation activities at SAJ’s water treatment plants.
FUTURE DIRECTIONMML® strives to continuously build sustainability through innovating its water management system. Besides expanding its rainwater harvesting efforts, in line with their sustainable water development goal, MML® is also constantly exploring other water conservation resources such as tube well water. Energy conservation in natural gas and electricity continues to be part of the brand’s sustainability activities.
Other factors in consideration are:
- The National Green Policy – formulated by Ministry of Energy, Green Technology & Water, Malaysia
- Global Sustainable Green Development
- Benchmarking within the industry
In 1964, industry experts from Japan, Italy and France were brought in to pioneer world class technology and stringent quality management in the start up of MML® – Malaysia’s first mosaic plant. Today MML® is a world-recognised award winning brand in luxury ceramic tiles, gracing the floors and walls of residential and commercial projects around the world.