Cycle Parking Circularity and Traceability

Falco has been a family company with its own production site in the Netherlands for over 70 years. Sustainability was in our DNA from the very beginning and this is reflected within our complete range of modular cycle parking and shelter products, all designed with full circularity in mind.

Circularity Meaning

What do we mean when we talk about “circularity”, especially within the cycle parking and shelter industry? Or when we say that we are working to become a more ‘circular organisation’?

For us right now, circularity means designing, manufacturing and supplying cycle parking products with the future in mind, so that they can be used time and time again, and then given a new life into new cycle parking products or components once our clients are finished with them.

Circularity requires a mindset shift, from the way we design, create and re-use cycle parking, and also to what we do with them once they have reached the end of their life.

The Circular Economy – What is it and why it’s important?

A circular economy is a systemic approach to economic development designed to benefit businesses, society, and the environment. A circular economy is an innovative approach to a traditional linear economy (make, use, dispose) whereby we keep resources in use for as long as possible, extract the maximum value from them whilst in use, then recover and regenerate products and materials at the end of each service life.

So Circular Economy intends for a world without waste. We must ensure that raw materials, parts and products retain their value. This also means that if we really want the concept to work, we must all work together!

Circular Economy isn’t just about raw materials or pollution alone, it is also about entrepreneurship - fulfilling business through value creation, financially and socially, innovation and better customer relationships.

Falco intends to be at the forefront of cycle parking Circular Economy, which is inextricably linked to the product range and it’s commitment to stimulate the use and comfort of bikes. Thus contributing to sustainable mobility.

Cutting a long story short - circularity is a new way of thinking! But above all, by doing it together!

Renewable Energy

Renewable energy sources such as the sun and wind do not cause air pollution and this type of energy is ‘inexhaustible’ in contrast to coal, oil and gas. It is this reason alone, Falco has invested in 1787 high-tech solar panels which are installed across our offices and production facilities.

This mass installation ensures Falco is a completely energy self-sufficient company.

In addition, a windmill installed at the front of the building provides even more renewable energy to the business. Furthermore, all lighting has been replaced with sustainable LED lights.

Durable Materials

Wherever possible, Falco utilises sustainable materials throughout its product ranges. Falco is one of the first companies in the Netherlands to become FSC certified. This means that all wood is accredited to the FSC quality mark of the Forest Stewardship Council®. Falco BV is certified under registration number: CU-COC-008530 and the Falco subsidiaries in the United Kingdom, Germany and Denmark can also confirm the certification status.

In addition to wood, steel is also a common material used throughout the product range and is 100% recyclable (even when galvanised). Corten steel is also used at Falco which again, is 100% recyclable, boasts low CO2 emissions and last just as long as regular steel!

Sustainability and Circular Products

All products ranges are contemporary and durable, typical of a Falco product. For over 60 years Falco has been at the forefront of the cycle parking and street furniture market and has built up a renowned reputation for manufacturing products that exceed in both design and durability.

Falco’s operations have supported the Circular Economy for many years, simply manufacturing products with environmentally friendly products, that can last for decades and at the end of the product life can be 100% recycled and manufactured back into a brand new product. By hot-dip galvanising and powder coating steel, significantly enhances the lifespan of the product and retains its value for as long as possible. All unused steel accumulated throughout the manufacturing process is conveniently collected and sent back to a steel recycling company. In addition, more and more products are available designed in such a way, that individual parts can be easily replaced without affecting the rest of the product and increasing the product lifespan.

Falco is researching even more possibilities when it comes to product circularity and the circular economy. Product development is a crucial aspect to support this. It is the intention of Falco, to design products that can rotate even more productive in the circular economy. Researching designs for even longer life, for (dis) assembly, refurbishing and remanufacturing, but also for repair and maintenance and for (clean and high-quality) recycling.

Sustainable Employer

In addition to the requirements of ISO 14001, Falco has invested heavily in sustainable energy across its own series of production machines and fleet of transport vehicles - with its aim to manufacture all products in its own factory without the need to outsource.

In 2018 Falco installed a state-of-the-art powder coating facility, essentially directly controlling the finished product from each line, improving product traceability and improving client lead times. By keeping all operations in house, provides Falco with a greater level of quality control and a significant reduction in unnecessary transportation. Falco employees work in a modern welding fume extraction facility, with separate water extraction and an excellent and safe working environment. Even better still, this initiative is great for employing a workforce from the local region!

Falco’s own fleet of transport vehicles comply with Euro V and forms part of a wider strategic plan of investments into its manufacturing, delivery and installation departments. All vehicles only carry out the required journey in question, with numerous deliveries combined into one journey, to reduce unnecessary transport.

Falco is pleased to report its staff turnover is exceptionally low and as a positive and proactive employer, Falco continuously invests into employee training and personal development. In addition, Falco has supported numerous apprentices and provided work experience opportunities to support the next generation into finding employment.

Moving forwards, a graduate from University Twente has identified ways Falco can improve its circularity through product design and research, use of materials and sustainable energy.

John Wermink has been employed as a Circular Manager at Falco since the 1st April. Johns role over the forthcoming years is to continuously develop Falco’s support to the Circular Economy. For you, but also for the generations to come!

Falco’s Circular Journey

Falco started the green energy transition more than 24 years ago. Large energy consuming machines have been directly replaced with more economical models, whilst performing the same high standard.

Renewable energy sources such as the sun and wind do not cause air pollution and this type of energy is ‘inexhaustible’ in contrast to coal, oil and gas. It is this reason alone, Falco has invested in 1787 high-tech solar panels which are installed across our offices and production facilities.

Wherever possible, Falco utilises sustainable materials throughout its product ranges. Falco is one of the first companies in the Netherlands and United Kingdom to become FSC certified. This means that all wood is accredited to the FSC quality mark of the Forest Stewardship Council®. Falco BV is certified under registration number: CU-COC-008530 and the Falco subsidiaries in the United Kingdom, Germany and Denmark can also confirm the certification status.

In addition to wood, steel is also a common material used throughout the product range and is 100% recyclable (even when galvanised). Corten steel is also used at Falco which again, is 100% recyclable, boasts low CO2 emissions and last just as long as regular steel!

This mass programme of improvements ensures Falco is a completely energy self-sufficient company. In addition, a windmill installed at the front of the building provides even more renewable energy to the business. Furthermore, all lighting has been replaced with sustainable, motion activated, LED lights.

This energy transition has saved us 60% on our carbon footprint. We continuously monitor this footprint and have a multi-year reduction plan.

The UK Government targets 65% circular procurement by 2035. And from 2050, we must be all climate neutral.

The R Ladder

The R-ladder provides a systematic view of circular strategies other than merely recycling (e.g. reuse, repair, leasing and sharing).

At Falco, we continuously assess at which step of the R-Ladder that can be worked on to keep the quality and value of the final product high.

RE-FUSE and RE-THINK

Falco rethink the manufacturing process to use more and more materials which has a less percentage of Raw material component. For example, our new Steel has increased its percentage of scrap steel from 20% up to 35%. Our goal is green steel that’s made of scrap metal and melted in an electric oven, powered by sustainable energy.

RE-DESIGN

At the design stage, we take into account the formation of a cycle parking product. Is it consuming too much raw material, can the product be re-designed to provide better functionality. Can the end product be reused or re-separated to form a different product.

RE-DUCE

With the help of our EPD (Environmental Product Declaration) and LCA (Life Cycle Assessment) calculator we are able to see where we can reduce energy consumption or material. We also examine the footprint of bio-based materials and see if this can reduce our total footprint.

RE-USE – in the same function

Falco products can be used in a second life phase, still offering the same function. For example, we take back a cycle rack after a few years, repair, refurbish and then re-sell it to a second customer.

RE-PAIR – maintenance and repair

To keep the value of the products at the highest level, they need to be regularly maintained. We engage with our client to offer a maintenance contract (where required) or advise on the correct maintenance procedure to enhance the product lifespan. This works well for FalcoLevel two-tier cycle parking and our customer has a good working product which retains its value.

RE-FURBISHED – modernising an older product

The ideal situation is always re-use - imagine a cycle rack that has too much damage to the steel structure, Falco are able to replace specific parts, rather than replacing the whole product. When a product is no longer wanted, it can be refurbished back to the manufacturers original condition, rather than discarded.

RE-MANUFACTURE

Manufacturing a new product using recycled materials. For example, we recycled old pinewood purlins from an old shelter as cladding for a new shelter. Because we had to ensure that the recycled wood would be durable enough to re-use, the pinewood was put through a thermal modification process. We also calculated the footprint of this process.  

RE-PURPOSE

Using products again but in another purpose. This is similar to remanufacture, only this time the product is re-used for another purpose other than the one it was originally manufactured for. Take dismantled polycarbonate sheets and wooden pallets, this material has been re-used and incorporated into greenhouses and wooden sheds.

RE-CYCLE

Ultimately, when a product reaches the end of its lifecycle and is designed with circularity, it can be sent back to our manufacturing facility. Our recycler brings back the steel to manufacturing conditions and that’s why the number of re-used steel in Falco products rose from 20% to 35%.

RE-COVER

We try to use all of our materials as long as possible and try to prevent the last scenario - which is waste. We concentrate on the useful application of materials that would otherwise end up in landfill. We also have a reduction and re-cover plan in place in line with our ISO 14001 accreditation.

FSC® all wood is FSC® accredited, meaning that all Falco products utilising hardwood will now be manufactured from 100% sustainalbe hardwood as standard – this includes all our shelters and stores, seating and general street furniture.

Carbon Footprint step three. A certificate which explains the footprint of our company and al the products we manufacture. We calculated with precision, we have a reduction plan for all emissions. This also helps to lower the carbon footprint of our products.

ISO 9001 is a certificate of the quality of our management system.

ISO 14001 is a certificate of the quality of our environmental management system.

VCA and SCL (Safety culture ladder) proofs that we value safety and want to be a sustainable employer.

EN-1090 is a certificate proving the quality of the welded construction.