Novo Nordisk in Kalundborg is one of our factories which is still expanding rapidly. This means that more water and energy are needed. Again in 1998 we therefore focused on consumption of these resources. With the current increase in productivity, water consumption would grow by 10% annually. However, much work has been done to cover some of the increased requirement by saving water elsewhere in production. This also applies to energy. We have set the ambitious target over a three-year period of cutting the volume of water and energy by a minimum of 15% per year per unit produced. This target was reached in 1998, and the actual increase in water and energy consumption was thus less than the expected 10%.

Achieving this target is especially due to the fact that the environment and consumption of resources are higher on the agenda, in terms of stronger management focus as well as our employees' active participation.

Address

Environmental management to strengthen efforts
The green accounts cover the most important environmental aspects of the factory. Besides consumption of water and energy they include impacts on the external environment such as odours and emissions of enzyme dust, as well as treatment and disposal of liquid waste, primarily biomass and waste water.

In Kalundborg enzyme production accounts for by far the greatest consumption of resources and the most significant environmental impact. In 1998 Enzyme Business has therefore initiated the establishment of an environmental management system based on ISO 14001. In 1999 all environmental factors in the area will be mapped, as the basis for the design of the system. This systematic effort involves the active participation of all production staff. According to the plan the environmental management system will be ready for certification by 2000.

Reduced consumption of ground water
Sufficient quantities of clean drinking water are important both to the residents of the municipality and to our production. In order to conserve ground water, in 1998 we concluded an agreement with the Municipality of Kalundborg on receiving more surface water from Lake Tissø. In relation to our production, consumption of drinking water in 1998 was 14% less per unit produced than in 1997.

Recycling of biomass
We have always given high priority to the recycling of biomass as fertilizer (NovoGro^®). As from the autumn of 1999, on the basis of new general regulations from the Danish National Agency of Environmental Protection, it will no longer be possible to spread liquid organic waste on fields in Denmark during the period from the beginning of October to the end of January. In 1997 we therefore established a plant to concentrate the liquid NovoGro^® into a solid fertilizer product, NovoGro^® 30. This plant has now been in operation for more than one year and experience so far is very positive. However, we will continue to spread liquid NovoGro^® via the permanent pipe network. The optimum distribution between solid and liquid biomass will be determined on the basis of a life-cycle analysis to take place in the spring of 1999.

Enzyme dust in air emissions
The fermentation plants are the main source of emissions of enzyme dust to the air. Today this air is led through a biofilter, which significantly reduces the concentration of enzyme dust. By agreement with the County of Western Zealand, over the past five years we have carried out a number of trials of further purification of fermentation emissions. These trials were concluded and reported to the authorities in 1998. The purification effect of the biofilter today exceeds 90%. Eliminating the remainder will besides major investments and higher operating costs also increase environmental impacts in other areas, particularly due to a higher energy consumption.

Energy
In 1998 we concluded an agreement with the Danish Energy Agency on increased investment in energy-saving measures over the next three years. In Kalundborg the first investments took place in 1998, and a number of further energy-saving projects are being assessed. The project will run until the end of 2000. In 1998 we also concluded an agreement with Sydkraft in Sweden on the purchase of electricity produced by hydroelectric power stations.

Investments in the environment
In 1998 DKK 21 million was invested in environmental improvements. Most of this investment was devoted to plants for treatment of biomass and waste water.

Dialogue with neighbours
Our most important environmental task in Kalundborg is to ensure that we are at the forefront of the authorities' requirements. However, we also do a lot to ensure an ongoing dialogue with the local community. We wish to be good neighbours and to react to complaints. In 1998 we received only two complaints from neigh-bours concerning bad odours. This is a significant improvement from 1997 when we received 20 complaints. This is primarily due to implementation of a number of improvements to our waste water treatment plant and the treatment of biomass which previously caused a number of bad odours.

Accidental releases and breaches of regulatory limit values
In 1998 there were five cases of accidental releases at the factory in Kalundborg. Three cases of release of NovoGro^® to the land outside the permitted spreading areas were registered. These were due to defective pipe connections. In all cases the release was collected and the damaged pipes repaired. On two occasions hydraulic oil and waste water containing ethanol were spilled on the ground.

In both cases the soil was removed and sent for controlled destruction. None of the five accidental releases had a negative impact on the environment.

In 1998 two breaches of the dosing limits for spreading of NovoGro^® were regis-tered. This is a significant improvement against 1997 when there were 33 breaches.

Health and safety
In 1998 we have put more focus on our health and safety work. This has made a positive contribution to reducing the number of occupational injuries in the entire area. In some areas a reduction of up to 25% was achieved. In connection with the design of our new insulin recovery factory we will make sure that all known health and safety problems are tackled at this early stage. In 1998 we described all problems and agreed on methods for monitoring the targets. In the enzyme area the important work to prevent employees from developing enzyme allergies has continued. We have decided to conduct two safety campaigns in 1999, to focus on attitudes to health and safety and on responsibility for one's own safety.

Consumption of resources
Water consumption: 2,266,000 m³
Energy consumption: 1,520,000 GJ
Raw materials consumption: 155,000 tons

Approximately half of our raw materials are agricultural produce containing starch and protein, and less than 1% of the total consumption of raw materials is substances which are hazardous to the environment or to health.

Discharges to the environment

Liquid waste streams
Liquid waste streams from the factory are divided into two categories:
¥ Biomass comprising nutrient residues, microorganisms and water
¥ Waste water containing small quantities of organic material and nutrient salts.
95% of the nitrogen and 99% of the phosphorus are present in the recycled waste streams.

NovoGro® 30: 97,300 m³
Liquid NovoGro®: 283,000 m³
Converted to liquid NovoGro^® the total quantity is equivalent to approximately 1,206,780 m3. NovoGro^® is the spent biomass generated when enzymes are re-covered from the fermentation broth. It is treated with heat and lime to kill all microorganisms and inactivate product residues. NovoGro^® is used as organic agricultural fertilizer. The Kalundborg factory handles biomass from the factories in Kalundborg, Copenhagen and Bagsværd, and the stated quantities of NovoGro^® are total figures for the three factories. With the biomass 914 tons of nitrogen and 544 tons of phosphorus are recycled from the liquid waste.

Yeast cream: 42,500 m³
Yeast slurry is the spent biomass obtained when insulin is recovered from the fermentation broth. The yeast slurry is heated to kill the yeast cells and lactic acid bacteria are added to conserve the liquid. This product is then called yeast cream, and it is used as a protein-rich feed supplement for pigs. With the yeast cream 558 tons of nitrogen and 146 tons of phosphorus are recycled.

Waste water: 1,749,000 m³
The quantity of waste water has risen by 5% from 1997 to 1998. This is not due to higher water consumption but to an actual larger volume of waste water as a consequence of the dewatering of the biomass into the solid product NovoGro^® 30. The waste water is treated in our biological waste water treatment plant so as to reduce the content of organic material and nutrient salts. The treated waste water is then led to the municipal treatment plant and from there to Jammerland Bay.

In 1998 we established a flotation plant to treat our biologically purified waste water. This plant was commissioned in January 1999. In 1998 we continued the trial with co-treatment of waste water from the factory and the municipality at the Central Treatment Plant of Kalundborg Municipality. Before the close of 1999 we must document that the nitrogen concentration can be brought down to a satisfactory level, so that the municipality can comply with its own discharge requirements. It must also be assessed whether co-treatment has an overall positive environmental impact.

Solid waste: 3,990 tons
In the period 1996-1998 the quantity of recycled waste has fallen by 36%. This reduction is due to a decrease in the quantity of pancreatic glands from pigs, from which insulin is extracted.

From 1997 to 1998 the quantity of waste for controlled destruction rose by approximately 60%. This increase is related primarily to a new enzyme formula-tion, whereby the first batch of cleaning water from production is sent to Kommunekemi. Furthermore, the volume of recycled organic solvents has risen by 110%. This increase is due to recycled ethanol from new production.

Emissions to air

Organic solvents: 39 tons
All plants using organic solvents, mainly ethanol and acetone, are equipped with recycling facilities in which the impure solvents are recovered to the greatest possible extent for reuse in processes.

Enzyme dust
The enzyme concentration in the emissions from fermentation varies between 0.00008 and 0.1 mg/m³. In other emissions the enzyme concentration is less than 0.002 mg/m3. The Danish National Agency of Environmental Protection has published a provisional limit value for enzyme dust in the environment of 3 nanograms (1 nanogram = 0.000001 mg). The factory's present contribution to the enzyme concentration in the environment is approximately 5 nanogram/m³. Our dispensation from the County of Western Zealand has been extended to July 1, 1999. In this period we can further document the operation of the biofilter which reduces the concentration of enzyme dust in the emissions to air. On this basis we will find a solution, together with the County, which is both financially and environmentally sustainable.

Odour
The company's emissions to the environment may not exceed 30 odour units/m3 (OU). On the basis of odour measurements in 1998 the production facilities in normal operation contribute approximately 10 OU/m³. The number of odour units does not in itself indicate the nuisance level of the odour, since it also depends on its nature. For comparison, in an ordinary street environment 50-400 OU/m3 have been measured.

Noise
The company's contribution to the noise level outside our boundaries may not exceed 45 dB(A) during night hours. This corresponds to the noise in a room where there is neither music nor conversation. We are subject to a requirement for annual noise measurements and annual calculation of the noise contribution at three selected receptor points around the factory. Measurements for 1998 show that the company contributes 45.8 dB(A).