Sustainable Development

Sustainability – from buzzword to concrete implementation in product development

Sustainability is more than just a buzzword—it is the foundation for future business success. Sustainable product development involves considering the entire value chain: from conception to manufacturing and use to the end of the life cycle. At BUSSE, we specialize in transforming these complex challenges into concrete, holistic solutions. We guide you through the process of strategically and successfully implementing sustainable product design.

Our expertise in sustainable design

As experienced experts in environmentally friendly product development, we offer you a unique service package. Our interdisciplinary approach ensures that all relevant aspects are taken into account from the outset in order to achieve not only ecological but also economic and social goals.

• Bionics & lightweight construction: Reducing material consumption and optimizing structures based on nature's example.

• Sustainable material concepts: Selecting environmentally friendly, durable, and recyclable materials.

• Implementation in development: Integrating sustainability criteria into every step of the design process.

• Training & consulting: Knowledge transfer and strategic support for your team.

What makes a product truly sustainable?

The sustainability of a product is influenced by various factors, the weighting of which varies depending on the application. Packaging requires different criteria than a durable electronic device.

The most important factors are:

• Durability & repairability: Robust construction and easy maintenance extend product life.

• Material efficiency & energy efficiency: Less resources and lower energy consumption in production and use.

• Recyclability & low hazardous substance content: Use of recyclable materials and avoidance of harmful substances.

• Renewable raw materials: Use of biodegradable or renewable materials.

Time weighting of sustainability factors

The relevance of sustainability factors changes over the course of a product's life cycle. However, most of the crucial decisions are made at the beginning of product development.

The planned service life is a key indicator for selecting the right strategy. Our charts visualize these relationships.

The key is to ask the right questions at the right time:

Materials & energy requirements

Choosing the right material is crucial for sustainable development. We consider not only the properties of the material, but also the total energy consumption throughout its life cycle—from manufacturing and processing to transportation and recycling. Transporting materials to production facilities and finished products to end customers plays a significant role in the carbon footprint.

A few examples illustrate this:

• Aluminum: The initial production of aluminum is very energy-intensive. However, it is extremely easy to recycle, reducing energy requirements to a tenth. A closed material cycle is essential here.

• Steel & glass: These materials are comparatively energy-efficient to produce and can be recycled very well.

• Plastic: One of the main advantages of plastics is their low density. The “material-bound energy requirement” describes the energy stored in the raw materials such as crude oil or cellulose (for paper).

Plastics & Recycling

The trend toward plastic recycling is unmistakable, with the proportion of energy recycling rising sharply. However, we believe that material recycling is the much more sensible method. We distinguish between three main types here:

• 1. Material recycling: This involves collecting, shredding, and recycling single-type plastics, for example, through injection molding or adding them as recyclate to new products.

• 2. Raw material recycling: Mixed plastics are converted into high-quality oil through heat. However, this process is very energy-intensive, which is why it is rarely used.

• 3. Energy recycling: The high calorific value of plastic is used to generate energy. Instead of fossil fuels, plastic waste is used to fire blast furnaces, for example, but this produces problematic, toxic dust that must be disposed of in landfills.

Use of so-called sustainable materials

In principle, almost any product can be made from recycled materials. However, the associated consequences must be considered at the outset of product development. It is important to understand that simply replacing a plastic with a bio-based material does not automatically make a product more sustainable.

Although such substitute materials offer advantages in terms of resource conservation, they can also have disadvantages:

• Fluctuating material properties: Bio-based or recycled materials may have lower strength properties.

• Increased material usage: To ensure technical functionality, thicker walls and thus more material may be required.

• Availability: The availability of the desired material is a decisive factor.

• Limited recyclability: Additives such as natural fibers often make these materials non-recyclable.

• Aesthetic defects: Color variations and visual defects could lead to a product being disposed of prematurely, even though it is still fully functional.

Conclusion

Sustainability in product development is much more than an ethical obligation—it is a decisive economic factor. Environmentally friendly and durable products strengthen your market position and increase customer demand.

But true success requires a holistic approach that takes ecological, social, and economic aspects into equal consideration. There is no standard solution. As we have seen, in some cases it can be more sustainable to deliberately choose high-quality, classic materials in order to create a product of exceptional durability and robustness. A single product with a long service life is often more sustainable than two that have to be produced, used, and recycled in quick succession. It always depends on the specific application and context of use.

Ready for your sustainable product development? Contact us today for a no-obligation consultation.