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September/October 2013
Your guide to adopting green manufacturing practices
Lighting savings slide down easy Texas plants fans cool and dry Electronic descaling
Giants footprint shrinks in the wash

Mary Ellen Mika relays how Steelcase reduced water, energy, cleaners use with counterflow wash system
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Screen image simulated. Offers avail. for corp-liable customers only. Activ. Fee: $36/line. Credit approval req. Early Termination Fee (sprint.com/etf): After 14 days, up to $350/line. Phone Offer: Offer ends 9/30/13. While supplies last. Taxes and svc charges excluded. No cash back. Req. activation of all same model phones on same account in one sales transaction. Data: Addl charges apply for premium content/downloads. Includes select e-mail. Usage Limitations: Sprint may terminate service if off-network roaming usage in a month exceeds: (1) 800 min. or a majority of min.; or (2) 300 MB or a majority of KB. Prohibited network use rules apply. Engaging in such uses will not result in throttling but could result in adverse action. See sprint.com/termsandconditions. Other Terms: Offers and coverage not available everywhere or for all phones/networks. Restrictions apply. See store or sprint.com for details. CL Port-in Svc Credit: Offer ends: 9/30/13. Available online, via telesales, in participating Sprint Stores, and direct & indirect business channels. Purchases from other national retailers are not eligible for svc credit. Requires port-in from an active number (wireless or landline). Svc credit request must be made at https://www.sprintportcredit.com within 72 hours from the port-in activation date or svc credit will be declined. Must remain active with Sprint Business for 61 days to receive full svc credit. Excludes upgrades, replacements and ports made between Sprint entities or providers associated with Sprint (i.e. Virgin Mobile USA, Boost Mobile, Sprint As You Go and Assurance), telephone numbers active on Sprint within the previous 60 days, all Individual-liable plans, Seasonal Standby plans, all plans with an MRC $10 or less, Business Freedom plans, M2M plans, special Government plans, and select custom pricing plans. May not be combinable with other offers. Port-in Payment Expectations: If the svc credit does not appear on the rst or second invoice following the 61st day, visit https://www.sprintportcredit.com and click on Wheres My Service Credit. Other Terms: Offers and coverage not available everywhere or for all phones/networks. Restrictions apply. See store or sprint.com for details. Nationwide Sprint Network reaches over 278 million people. Sprint 3G network reaches over 275 million people. 2013 Sprint. All rights reserved. Sprint and the logo are trademarks of Sprint. Other marks are the property of their respective owners.
September/October 2013 Vol. 4 No. 5
Your guide to adopting green manufacturing practices

publishing affiliate of the Fabricators & Manufacturers Association, International
Contents
Features Cover Story 20 Steelcase shrinks water, energy, cleaners use in the wash:
Counterflow wash system reduces giants environmental footprint, makes deep imprint
Steelcase Sustainability and Energy Manager, Global Procurement Mary Ellen Mika initiated Steelcases collaborative green partnership with chemicals supplier DuBois. The collaboration led to a significant reduction of the office furnishings manufacturers water, energy, and chemicals consumption in its metal components finishing pretreatment process and, hence, its global environmental footprint. Steelcases c:scape metal storage enclosures, tables, and walls, some shown here, are cleaned and prepared for powder coat application in the Kentwood West metals finishing plant.
On the cover: Cover photography of Mary Ellen Mika by Craig van der Lende for Green Manufacturer.
20
28
White Castle manufacturer lights up at plants lighting, 28 controls retrofit

Iconic White Castle, established in 1934, manufactures its own cookware equipment and fixtures at its Porcelain Steel Buildings (PSB) division. The PSB plants lighting retrofit with lighting controls has already realized a $60,000 cost savings that slid down easy.
32 Technology Spotlight
New system combines high-efficiency chiller with hybrid solar technologies and leverages waste heat to put the freeze on building energy use and costs.
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34 Texas plants fans cool workers, reduce drying time
High-bay fans installed in a Texas manufacturing facility not only helped regulate the temperature, they also cut process drying time in half.
38 Control scale to optimize HVAC equipment energy efficiency

2013 FMA Communications, Inc. All Rights Reserved.
It costs U.S. industry billions of dollars a year to control and remove the limescale from heat exchangers, evaporative coolers, boilers, and chillers. Electronic scale prevention technology can help.
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green MANUFACTURER September/October 2013
Departments

Surveying the Greenscape

In Influencing the future of the Earth for good, Editor Kate Bachman shares her experience interviewing Steelcase CEO Jim Hackett and relays how Steelcases supply stream dynamics led to quantum leaps in achieving its sustainability goals.
8 10
Re: Readers respond to Efficiency is power. Ecosavvy Newsmakers

New technology cleans polluted glycols; Sustainable Biodiesel Certification program launches; China Green Manufacturing Summit nears; Dell commits to waste-free packaging stream; Metal fabricator wind-powers its plant; Trellis Earth Products moves production from China to New York.
16
Plant Applications
Phosphate pretreatment recycling eliminates trailer-makers wastewater concerns.
18
On the Hill
DOE takes next step on energy efficiency standards for industrial pumps and nonhazardous classification for wipes to save up to $27.8 million annually, according to columnist Stephen Barlas.
43 44
Green Manufacturer Network Connections Reusable Pallet Directory

Why discard when you can reuse?
46 Greenovations Mechano-electret filter media captures submicron-sized particles, reduces

energy costs; ERV products dehumidify makeup air.
47 49 50
Product News Advertisers Index Under Cover

Bridge over onion waters is constructed of recycled plastic detergent bottles, shampoo bottles, milk jugs, car bumpers, and dashboards.
Note: To opt for a digital version, visit www.greenmanufacturer.net and click on Subscribe, then Digital Version.
Printed on recycled paper, 30% postconsumer
Surveying the Greenscape
Influencing the future of the Earth for good

And the power of supply stream dynamics
s a journalist, I have had the honor and privilege of interviewing some of the most brilliant, influential, and creative leaders on Earth. Then Ive had the opportunity to relay how they are helping save the planet for human habitation. Five years ago I interviewed James Hackett, CEO of Steelcase, the largest office furnishings manufacturer in the world. The concepts and philosophies he discussed are still remarkably relevant today. (To read the interview transcripts, visit www.greenmanufacturer. net/ar ticle/management/Steelcaseceo-james-hackett-shares-philosophysustainability-strategy.) On the way to his office, I got to try out a hybrid treadmill/desk at which employees can work and exercise simultaneously. Once in his office, I was invited to sit in his chairthe ultimate in comfort and work facilitation, of courseto view how he communicated in real time with his design team in Palo Alto, Calif., via videoconferencing. For the interview, we lounged in a caf booth, one of the seating arrangements the company was testing out in its living-laboratory headquarters. While sitting across from him, listening to him describe his macro concepts and vision for the company, I could not help but feel that I was in the presence of greatness. I remember straining to soak it all in, mentally dog-earing every sentence, rapidly jotting noteworthy phrases, and checking and rechecking my recorder to make sure it was capturing everything
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he said. It was not only that his word choices and phraseology were stimulating, but also that he introduced to me concepts and predictions that have emerged as sustainable truths.
Surviving the next economic downturn includes implementing green manufacturing.

He spoke of accepting the reality of a constantly changing, highly turbulent environment; not just riding out the waves of difficult times, but emerging from them more fit to survive the next onslaught; delayering complexity; parallels from geology to current economics; predictive mutations and historical new world constructs; and how technology has changed work from a place you go to a thing you do.
Green at Every Turn

Most germane to this publications mission, Hackett foretold of the realization among manufacturers that surviving the next economic downturn includes implementing green manufacturing. The company had just embarked on its 2006 plan to reduce its environmental footprint in leaps and bounds by its centurial anniversary in 2012. He spoke of producing products designed to be easily dissembled at the end of their useful lives to enhance a cradle-to-cradle life cyclea new concept to me at the timeand embracing sustainability at
every turn, including water conservation, energy use reduction, emissions and VOC reduction, and responsible waste management. While Hackett has presided over the company, Steelcase has evolved and sustained long enough to mark its 100th anniversary and achieve its sustainability plan goals. The company has grown more ecoresponsible and responsive to an increasingly mobile, technological, and conscientiously purchasing society. It has emerged as a significant environmental leader, influencing its supplier manufacturersand in some cases, being influenced by them. Be sure to read this issues cover story, Steelcase shrinks water, energy, cleaners use in the wash, p. 20, which describes how Steelcases supply stream dynamics led to quantum leaps in achieving its sustainability goals. Considering Steelcases widespread influence and resulting environmental benefits begs the question: How can you influence your supply network for the environmental good?
Kate Bachman, Editor Got thoughts? kateb@greenmanufacturer.net
Be sure to receive news and updates via Twitter from Editor Kate Bachman (www.twitter.com/greenmanufacts)
Re:
Intersection of Economics and Environment
Your editorial Efficiency is power in Surveying the Greenscape [July/August issue, p. 6] was both educational and informative. That and your article How power metering empowers Toyota [p. 18] encapsulated a very critical messagethat being economically efficient and environmentally responsible in business practices are not mutually exclusive ideas. Exemplifying this is the scenario you discuss in which Toyota Production Systems energy reduction initiatives cut in half the energy required to produce a car. For so long we have perceived the adoption of solar power and alternative energy sources as trendy and perhaps even expensive, but as technology evolves, it would seem that this will not be the case for much longer. I see evidence of this concept in the reduction in environmental waste expenditures that manufacturers are beginning to see by implementing lean manufacturing principles. Thank you again for taking the time to express such an important message: the intersection of economically and environmentally beneficial business practices.
Kristie Karkanen
Published by FMA Communications Inc. 833 Featherstone Road Rockford, IL 61107 Phone: 815-399-8700 Fax: 815-484-7700 www.greenmanufacturer.net
Green Manufacturer Staff

President & CEO, FMA Edward Youdell Group Publisher Dave Brambert Editor-in-Chief Dan Davis Editor Kate Bachman Contributing Editors Tim Heston, Eric Lundin, Amy Nickel Senior Copy Editor Teresa Chartos Graphic Designer Jennifer Paulson Publication Coordinator Kelly Palmer Director of Circulation Kim Bottomley Circulation Manager Brenda Wilson
Data Verification Specialist Rhonda Fletcher Senior Fulfillment Specialist Anna Peacock Web Content Manager Vicki Bell Multimedia Specialist Sherry Young Senior Web Developer Jason Bartholme Web Developer Johanna Albee
Marketing Program Specialist Bishop-Wisecarver Corp. Pittsburg, Calif.
Green Manufacturer Advertising Sales

Associate Publisher Jim Gorzek Senior Account Representative Phil Arndt phila@greenmanufacturer.net
Powerful Efficiency
Just wanted to write to you and tell you that I loved the editorial, Efficiency is power, in the July/August issue. I completely agree that energy efficiency is the differentiator between the successful manufacturers and the notas-successful ones. We are a contract manufacturer specializing in sheet metal and tubular
Got thoughts?
Green Manufacturer is happy to publish your letters. Send your comments to kateb@greenmanufacturer.net. You must include your full contact informationfirst and last name, title, company, and address. We need your address for author verification, but we will print only your name, position, city, state; company name is optional. All correspondence will be considered for publication unless specifically requested otherwise and will be edited at the editors discretion. Letters written to advertise the benefits of a specific product or company will not be considered for publication.
racks for the data communication industry and also the solar energy industry. My twin brother and I are working hard to maximize our efficiencies in our manufacturing processes as well as our office culture.
Eddie Garcia
Classified Advertising Patricia DAmico patriciad@thefabricator.com Director of Accounting Bob Young Accounts Receivable Mary Simons
Green Manufacturing Network Advisory Board

Chair Bill Stough, Sustainable Research Group LLC First Vice Chair Aaron Mason, Hawkeye Energy Solutions Second Vice Chair Sue Max, Metcam Inc. Phil Baerenwald, JL Clark Charles Gerhardt, UL LLC Mary Ellen Mika, Steelcase Inc. Ryan Pennington, Freightliner Custom Chassis Corp. Board Members
Vice President A.G. Machining Inc. Moorpark, Calif.
Statement of Policy
As a publication of the Fabricators & Manu fac turers Asso ciation, International, Green Manufacturer seeks to be the information source for those who are responsible for driving the transition to environmentally friendly manufacturing. The policy of the publisher and this publication is to be non partisan, favoring no one product or com pany. The representations of facts and opinions expressed in the articles are those of the author and are not necessarily endorsed by the publisher and this publication. The publisher reserves the right to refuse advertising it deems inappropriate for publication in Green Manufacturer in cluding ads for classes of products and services not considered of significant interest to the readership. Publications of FMA Communications Inc. maintain a policy of keeping editorial and advertising separate to ensure editorial integrity that most benefits our readership. Editorial content, including feature articles and press releases, is determined solely by the publisher. Editorial content cannot be purchased, nor can it be used as a benefit of advertising dollars spent. Editorial is free-of-charge, subject to space availability, and open to all interested parties that submit items meeting our editorial style and format as determined by the publisher. Note: Some photographs appearing in this publication may be taken with safety equipment removed for photographic purposes. However, in actual operation, it is recommended that correct safety procedures and equipment be utilized. FMA Communications Inc. also publishes these other manufacturingrelated publicatons:
The FABRICATOR TPJ - The Tube & Pipe Journal Practical Welding Today The FABRICATOR en Espaol STAMPING Journal CIM - Canadian Industrial Machinery
Follow us @greenmanufacts
Hydraulic Institute working w/ACEEE, Alliance to Save Energy, NRDC, DOE on energy-efficiency stds. for clean water commodity-type pumps EPA to wipe away hazardous designation of disposable industrial wipes in Jan. 2014. Green brings out the best in the greenest. Find out who won the 2013 Green Manufacturer Product Innovation Awards!
Solar is now the fastest-growing energy source in the country, by 76% in 2012SEIA
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EPA confirms 18 toxic water pollution from coal ash sites have contaminated local water
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Ecosavvy Newsmakers
FABTECH, Greenbuild convention centers showcase their green
The center also has installed green, vegetated roofs atop the convention center. Forty thousand plants have greened approximately 15 percent of McCormick Places 1 million square feet of rooftop. St. Louis-based Green Roof Blocks, maker of portable green roof systems, performed the installation. It is the second-largest such installation in the U.S. The Pennsylvania Convention Center, site of this years Greenbuild convention Nov. 20-22, has committed to reducing its environmental impact on its operations and services: Low Environmental Impact Cleaners The center uses Green Seal-certified cleaning chemicals to improve the air quality and create a healthier indoor environment for building personnel and visitors. These include bathroom hand soap. Waste Reduction/Recycling The center uses single-stream recycling. In 2009 and 2010 the center recycled and diverted a combined 469.83 tons of waste from landfills. In addition, it serves its food and beverage with sustainable cutlery, hot/cold beverage cups, napkins, and plates made of 100 percent decomposable and biodegradable materials. Restroom paper products are made from recycled products. Automatic dispensers for water, soap, and paper products in the restrooms are intended to reduce waste. Lighting Automatic lighting has been installed to help reduce energy use.
The convention centers hosting FABTECH and Greenbuild both have made great green strides to create appropriate settings for the shows to be held in November. Chicagos McCormick Place, which hosts the 2013 FABTECH metal fabrication tradeshow Nov. 18-21, has made a showy presence of its sustainability efforts. In May the Windy City center switched to 100 percent wind energy by purchasing Green-e Renewable Energy Certificates (RECs) generated from wind power to match 100 percent of the annual electricity demand. In total, the center will purchase an estimated 130 million kilowatt-hours of wind power each year over the course of a new three-year REC purchase program provided by Sterling Planet.
Show-stoppers
Be sure to visit these Green Manufacturer advertisers at FABTECH and Greenbuild:
Association of Energy Engineers Big Ass Fans Orion Energy Systems Packsize SCA Schneider Electric Siemens Industry Solatube International TRUMPF Zing Enterprises
We are committed to having renewable energy as part of our comprehensive efforts to implement environmentally friendly, sustainable practices, said David Causton, general manager of McCormick Place, the nations largest convention center. Purchasing wind power helps our organization become more sustainable, while also sending a message to others that supporting clean sources of electricity is a sound business decision and an important choice in reducing carbon emissions with green power.
DuBois Chemicals Durr Ecoclean GAF Building Materials Industrial Maid Kimberly-Clark Professional
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Ecosavvy Newsmakers
GlyEco begins Type 1 recycled glycol production
GlyEco Inc., Phoenix, has completed initial technology upgrades and begun producing Type 1-compliant recycled glycol for commercial use. Its lab has shown the recycled materials comply with ASTM 1177 EG-1 standards, the same purity level expected of renerygrade glycol. The company will send samples out to independent third-party labs to verify its results. We can clean any type of used glycol to meet these standards, and that same material can be used, recycled, and used again indenitely, said John Lorenz, chairman and CEO. GlyEco Technology can clean polluted glycols from all ve waste-producing industries: HVAC, textiles, automotive, airline, and medical.
Aveda launches packaging collection, recycling program

Aveda, a professional botanical hair care brand based in Blaine, Minn., has introduced its new Full Circle recycling program in the U.S. The company has partnered with g2 revolution, a recycling innovations company, to allow customers to return Aveda packaging not accepted by some municipal curbside recycling programs to all 107 Aveda Experience Center retail locations in the U.S. The collected packaging is sorted to be recycled into reusable material, with the goal of eliminating waste and making it into new Aveda packaging or accessories. The company develops packaging with high levels of postconsumer recycled content that can be continuously cycled in the industrial world.
Randall Mfg. recognized as a 2013 Top Green Provider

Food Logistics magazine has named Randall Mfg., Elmhurst, Ill., as a Top Green Provider for its commitment to sustainable leadership and its investment in green products, including the new GREEN InsulWall. The modular, energy-efcient, reusable curtain wall system, made from recycled insulation, has a superior R-value, according to the company. The manufacturer launced a blog series in June entitled LEEDing Questions. At www.randallmfg.com/ warehouse, Todd Jessup, warehouse territory manager, asks a variety of design and build contractors a series of questions about todays green building trends and the products they see shaping the future of green buildings.
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green MANUFACTURER 11 September/October 2013
Ecosavvy Newsmakers
Clean Energy, Covanta open CNG fueling station
Clean Energy Fuels Corp., Newport Beach, Calif., a provider of natural gas fuel for transportation, and Covanta Energy Corp., a provider of sustainable waste management and renewable energy, have opened the first compressed natural gas (CNG) fueling station in Newark, N.J., built as part of a nationwide partnership between the two companies to expand the CNG fueling infrastructure across the country. The new station, built and maintained by Clean Energy on-site at Covantas energy-from-waste facility, supplies CNG fuel to refuse trucks serving communities and businesses in northern New Jersey and New York City. We are moving forward with a major program to replace our existing fleet of diesel-powered garbage trucks and street sweepers with new, cleaner-operating, CNG-fueled trucks, said Newark Mayor Cory Booker.
Sustainable Biodiesel Certification program launches

GreenCircle, Royersford, Pa., and the Sustainable Biodiesel Alliance (SBA) have announced the official launch of the Sustainable Biodiesel Certification program. The announcement came at Willie Nelsons 80th birthday party in Times Square, five years after the SBA kicked off with Nelson. We didnt realize how long it takes to create a certification program, but Im here today to tell you we have completed [it] with the help of GreenCircle Certified, said Kelly King, chair of the SBA. With the support of Nelson and other honorary SBA board members, including Woody Harrelson, Daryl Hannah, and Jack Johnson, the Sustainable Biodiesel Certification is poised to receive national recognition for evaluating and verifying sustainable alternatives to traditional petroleum-based fuels, GreenCircle reports.
Carbios collaboration supports creation of biotechnology laboratory for bioplastics

Carbios, a Paris-based green chemistry company specializing in the development of industrial bioprocesses and proposing new approaches for recovering plastic waste and producing biopolymers, has announced the signature of a 3.2-million-euro (about $4.1 million) collaboration with the National Center for Scientific Research (CNRS) and the Poitiers University. The project is part of the THANAPLAST private-public consortium on plastics, one of the largest projects in the field of plastics technology. Carbios is leading a team of participants from industry and academia that includes INRA, TWB, INRA Deinove, Limagrain, and the Barbier Group to find ways to reclaim plastics at the end of their useful life. The THANAPLAST SP-Carbios bioplastics cooperative biotechnology laboratory in Poitiers is the R&D center for the consortium. Its mission is to develop a biotechnology platform to be used in plastics technology.
Coca-Cola, WWF partner to advance sustainability stewardship

The Coca-Cola Co. and World Wildlife Fund (WWF) are working to advance the CocaCola systems sustainability stewardship with new global environmental goals and an expanded global partnership. These goals, which complement other Coca-Cola well-being and community commitments, focus on sustainable management of water, energy, and packaging use, as well as sustainable sourcing of agricultural ingredients through 2020. Building on the initial successes of their nearly decade-long partnership, Coca-Cola and WWF have agreed to extend their efforts by meeting new conservation and performance targets, promoting the integration of natures value into decision-making processes, and convening influential partners to help solve shared global environmental challenges.
Grainger opens LEED-certified, platinum-rated distribution center in Illinois

Grainger, a supplier of maintenance, repair, and operating (MRO) products serving businesses and institutions, has opened a new distribution center in Minooka, Ill. The 1 million-sq.-ft. facility serves as the companys new central stocking distribution center. This distribution center is one of the worlds largest LEED-certified, platinum-rated facilities for commercial interiors. It features a 2,200-sq.-ft. solar wall, which uses air and solar capabilities to help reduce energy consumption; energy-efficient lighting, along with motion sensors; electric automobile charger stations; and a recycling program initiated to collect cardboard and shrink wrap from operations.
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ABB director receives award from Green Parking Council

ABBs Cal Lankton, director of the companys Electric Vehicle Charging Infrastructure for its North American operations, has received the 2013 Pioneer Award for Sustainability from the Green Parking Council (GPC). The award recognizes leaders of the parking industrys transition to an environmentally conscious business model. This award can be shared by everyone at ABB who is working toward sustainable mobility, from the EV team deploying charging infrastructure to our cross-divisional work supporting a smarter grid, Lankton commented.
Ecosavvy Newsmakers
Construction Specialties, Earth911.com launch recycling locator
Construction Specialties (C/S) and Earth911.com have launched the Construction Specialties recycling locator at www.c-sgroup.com/corporate/ recycling#. The web tool addresses recycling of commercial building products and provides consumers with the information and resources necessary to recycle and dispose of C/Ss materials. The companies worked closely together to create the custom recycling tool that addresses C/S customers specic needs, including identifying and verifying new facilities that would take the companys materials, in addition to using Earth911s recycling directory.
Solatube Intl. launches rebranded website

Solatube Intl., Vista, Calif., has launched a new, rebranded website to support its line of commercial and residential products, including tubular daylighting devices. The site provides before-and-after photographs, a one-click residential dealer and commercial distributor locator, product information featuring the new Smart LED system, lighting comparisons, things customers should know before they buy, and FAQs.
ASSOCIATES
Smith Electric eet surpasses 700 vehicles, 5 million miles of operation

Smith Electric Vehicles Corp., a producer of allelectric, mediumduty commercial vehicles in Kansas City, Mo., has announced it has produced more than 700 of its all-electric Edison and Newton trucks, which have cumulatively generated more than 5 million miles on the road. This milestone shows that the adoption rate of commercial electric vehicles by major global blue chip corporations continues to expand. According to the company, customers that work with Smith Electric to transform their eets save an estimated 70 percent annually on fuel and maintenance during the life of the vehicle and eliminate all vehicle-based emissions. The 5 million miles traveled by Smith Electric vehicles have offset an estimated 700,000 gal. of fuel, eliminating more than 10,000 short tons of greenhouse gases.
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Ecosavvy Newsmakers
J.W. Winco launches green roof project
J.W. Winco Inc., a supplier of standard industrial machine components, has begun installation of a green roof system on its New Berlin, Wis., facility. Benefits include recycling of rainwater and savings on cooling costs. The companys remodeling project has been approved under the Milwaukee Metropolitan Sewerage District (MMSD) Regional Green Roof Initiative. The green roof project will take approximately three weeks to be completed. Our existing conventional roof system was installed in 1993 and needed to be replaced, so we researched the possibility of installing a fully vegetated green roof system, said Mark M. Winkler, CFOoffice of the president of J.W. Winco Inc. The addition of the green roof is part of the companys effort to be a leader in environmental stewardship by reducing our carbon footprint and managing rainwater efficiently, while at the same time cutting energy costs, he added.
TRUMPF Inc. names new president/CEO

Fabricating machinery manufacturer TRUMPF Inc., Farmington, Conn., has named Dr. Lars Gruenert as president and CEO, succeeding Rolf Biekert. In this position, he is responsible for all of the companys subsidiaries and business operations in North America, including manufacturing, engineering, research and development, customer service, technical training, product sales, and applications. Gruenert previously served as executive vice president of TRUMPF GmbH + Co. KG and CFO of the Laser Technology/ Electronics business division. In this role he was responsible for the central departments IT and processes, purchasing, and organizational development. After 25 years with the organization, Biekert leaves to lead Maintecx, an independent fabricating equipment sales representative company and an exclusive distributor of TRUMPF fabricating equipment in the Midwest.
Gilchrist Metal Fabrication recognized by U.S. EPA

Gilchrist Metal Fabrication Co., Hudson, N.H., has been recognized by the U.S. Environmental Protection Agency (EPA) for powering its facility with 100 percent renewable energywind power. As a metal fabrication company, its no secret that we use a lot of power, said Jack Gilchrist, president. Not only is [wind energy] more sustainable for businesses and communities, but it also allows us to help contribute to green initiatives on both a local and national level.
T&M Associates adds staff

T&M Associates, Middletown, N.J., an engineering, consulting, and environmental services provider, has announced the addition of several energy consulting specialists to assist clients in navigating deregulated energy markets and securing more competitive and predictable pricing for their gas and electric service. Daniel Swayze, PE, CME, has been named senior vice president and regional manager of energy and utilities. He has more than 21 years of experience providing consulting and engineering services to private and public clients and has extensive experience developing solutions for energy efficiency, energy procurement, and renewable energy projects. Michael Mandzik, CEP, has been hired as director of energy procurement advisory services. Mandzik has more than 30 years of experience in the field of
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energy procurement, having worked previously as an instructor for the Association of Energy Engineers energy procurement professional certification program and as a marketer of energy futures for the New York Mercantile Exchange. Tara Pasca, CEP, has joined the company as energy procurement project manager. She has more than seven years of experience in the identification, analysis, and delivery of energy procurement strategies and retail market opportunities and has managed multimember aggregation groups and cooperative pricing systems (co-ops). Michelle Trumbetti has been named utility billing analyst with the companys Energy and Utilities Group. She is responsible for gathering historical usage data, analyzing utility energy usage and consumption, auditing commercial and industrial energy bills, analyzing tariffs, and monitoring commodity markets.
Evolucia opens new headquarters, R&D facility

Evolucia Inc. has moved to a 61,000-sq.ft. facility in Sarasota, Fla., to expand its operations. The facility serves as the companys world headquarters and center for research, development, testing, and manufacturing of LED lighting controls and fixtures. The company maintains its offshore international mass-production capabilities through its partnership with Leader Electronics and continues to develop contract manufacturing relationships in Radom, Poland, for distribution of its products into the European markets. New manufacturing and optical testing equipment has been installed at the facility, allowing the company to perform photometric, thermal, optical, and other product and component analysis internally rather than contracting this work to external organizations.
Ecosavvy Newsmakers
Trellis Earth Products moving manufacturing production from China to New York
Trellis Earth Products has announced it will move its manufacturing operations from China to its first U.S. manufacturing facility outside of Rochester, N.Y., with production set to begin in 2014. The company, a manufacturer of sustainable food service products, will invest $8.3 million in the new 80,000-sq.ft. facility, creating 189 jobs. The company will manufacture more than 50 million forks, knives, and spoons monthly at its new facility, as well as flexible products including clamshells, school lunch trays, and plates. All products will be made from its bioplastic blend that is composed primarily of plant starch, helping to reduce petrochemical consumption and lessening the burden on landfills.
China Green Manufacturing Summit scheduled for November

Apex Intl. will present the 2nd Annual China Green Manufacturing Summit 2013 on Nov. 14-15, 2013, in Shanghai. The event will focus on deepening the understanding of clean, energy-efficient, green, and sustainable manufacturing concepts while also serving as a platform for presenting the latest regulatory changes and sharing best practices. Topics to be discussed include incentives and regulations in China for the promotion of green manufacturing; sustainable manufacturing techniques for the pharmaceutical, chemical, electronics, automotive, and transport manufacturing sectors; energy-efficient supply chain and carbon management; manufacturing process design and development; and automation.
Dell commits to waste-free packaging stream by 2020

Dell Inc., Round Rock, Texas, has announced its sustainable packaging initiatives, including goals for a waste-free packaging stream by 2020 and a new wheat straw material that turns agricultural waste into boxes. The company is ensuring that 100 percent of its packaging is sourced from sustainable materials, including recycled and rapidly renewable content, or material that was formerly part of the waste stream, and that it is recyclable or compostable at the end of its life. Currently more than half of Dells packaging meets both these criteria. The company also announced it will begin using a new sustainable materialwheat strawin many of its cardboard boxes for notebooks originating in China.
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www.greenmanufacturer.net green MANUFACTURER 15 September/October 2013
Plant Applications
wastewater
Phosphate pretreatment recycling eliminates trailer-makers wastewater concerns

Situation
Bri-Mar Mfg., a manufacturer of hydraulic dump trailers in Chambersburg, Pa., was dealing with a growing concern over proper disposal of used phosphate pretreatment solution from its metal surface paint preparation line. By itself, the cleaning and pretreatment application process is pretty straightforward, said Kevin Kelley, president and CEO. The trick is what to do with the used phosphate solution after it hits the wash bay drain. The company historically had been treating and dumping the water, but in an effort to keep up with increasingly stringent regulations on sending wastewater to the borough, it began searching for a more environmentally friendly option. The closed-loop recycling process frees us from the limitations and costs imposed by our waste stream permit, Kelley remarked. As a result, we will reduce our chemical and water consumption by roughly 70 percent with nothing going down the drain. The system has freed up labor hours, since there are no more inspections of wastewater being sent to the borough. On top of that, by switching to PhosBite 101, the secret sauce to the CPR system, we are cleaning and degreasing in one step, said Lance Harringon, plant manager. Not only does this improve our cleaning process and the finish quality of our trailers, but we have significantly reduced our chemical and water consumption by recycling.
CPR Systems, A Division of T. George Podell & Co. Inc., 1400 S. Main St., South Bend, IN 46613, 800-897-7515, contact@cprsystemsonline.com, www.cprsystemsonline.com
Resolution
After a lot of research, Bri-Mar selected a CPR phosphate cleaning system from CPR Systems for its ability to recycle and reuse the pretreatment waste.
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On the Hill
DOE takes next step on energy efficiency standards for industrial pumps
Nonhaz classification for wipes to save up to $27.8 million annually
he U.S. Department of Energy (DOE) has taken the next step in establishing first-time energy efficiency standards for industrial and commercial pumps. The agency is in the process of putting together what is called a negotiated rulemaking committee composed of users, manufacturers, and environmentalists who ostensibly hammer out a standard which then flies through the rulemaking process, without any objections. The DOE had released a request for information in 2011 and then a framework document last February providing some direction on where it expects to go, in terms of the categories of pumps covered and the kind of metrics that could be used to set new efficiency standards. The pump manufacturers, represented by the Hydraulic Institute, are pressing for an extended product approach using an Energy Efficiency Index (EEI) that would take into account the pump, motor, variable-speed drive, and control and feedback systems. The association has been working with environmental groups such as the American Council for an Energy-Efficient Economy (ACEEE), the Alliance to Save Energy, and the Natural Resources Defense Council (NRDC) on consensus standards with those efforts focusing on clean water commodity-type pumps. However, environmentalists want to expand the types of clean water pumps to include double-suction and circulator pumps.
Clean water pumps represent about 90 percent of pump energy use.
The European Union (EU) already has a directive (Regulation 547/2012/ EC implementing directive 2009/125/ EC) on efficiency standards for clean water pumps, and the DOE generally tends to follow it. Charles Llenza, project manager for the rulemaking, said, We have sort of borrowed from their playbook a little until we get our footing with this rulemaking and the stakeholders input in the U.S. industry. The DOE estimates clean water pumps represent about 70 percent of pump sales by value and 90 percent of pump energy use. Those pumps can be used for chemicals and other liquids also, and so the DOE is considering tying chemical pumps into the new standardat least, to the extent any are used primarily for that end use. But wastewater, slurry, and API 610 pumps are outside the purview of this rulemaking. A major issue will be whether to include variable-speed drives (VSDs) in the standard. Greg Towsley, director, regulatory and technical affairs, Grundfos Pumps Corp., the Danish concern that claims to be the worlds largest pump manufacturer, wants VSDs to be included.
But Steve Rosenstock, senior manager, energy solutions, the Edison Electric Institute, which represents investor-owned utilities, said, EEI does not support establishing standards or test procedures based on pump performance with a variable-speed drive controller. Pumps are used in a variety of applications, and not all are a good fit for VSD.
EPA Wipes Away Hazardous Designation of Disposable Industrial Wipes

Industrial companies and manufacturers that use disposable wipes on solvent spills just got some good news from the U.S. Environmental Protection Agency (EPA). As of Jan. 31, 2014, those wipes no longer will be classified as hazardous waste, except in the case of wipes contaminated by trichloroethylene. This means that users no longer will have to manifest most disposable wipes when they are sent off-site, and they can be sent to nonhazardouswaste handling facilities. That will reduce costs. But the used disposable wipes have to be managed, while on-site, in closed
18
On the Hill
containers that are labeled Excluded Solvent-Contaminated Wipes. The wipes can be stored on-site no longer than 180 days. Solvent-contaminated wipes must not contain free liquids at the point of being sent for cleaning or disposal. Petitions from first Kimberly-Clark and then Scott Paper, the first arriving at the EPA in 1985, sparked this longruminated change. In 2003, according to the agency, the estimated respective annual market share was 88 percent for reusable wipes, which have never been classified as hazardous waste, and 12 percent for disposable wipes. The final rule will make disposable wipes more attractive. Disposable wipes that are then sent to landfills must meet a no free liquids standard. That must be met using what is called the Paint Filter Liquids Test (Method 9095B). EPA notes that generators do not have to conduct the test for every solvent-contaminated wipe. Rather, generators must ensure that if the test was performed, the wipe would pass. The EPA estimates that the final rule will result in a net savings for manufacturers of between $21.7 million and $27.8 million per year.
Stephen Barlas, a freelance writer based in Arlington, Va., can be reached at sbarlas@ verizon.net.
From Green Manufacturer Brief

News items from our e-newsletter
By Donna Bacidore, Contributing Writer
in a wind power capacity that meets 4.4 percent of this countrys electricity demands. Equally as impressive is that 72 percent of the turbine equipment installed last year, which includes blades, gears, and generators, is U.S.-made, making it a good job source as it employs an estimated 80,000 workers in this country. This almost triples the domestic manufacturing of turbine equipment, which was 25 percent in 2006-2007. In 2012 Texas led the country in wind power capacity additions, installing 1,826 megawatts (MW). Other states that added more than 1,000 MW last year are California, Kansas, and Oklahoma. 69,000 units across all the states. Distributed wind energy installations supply power directly to local grids near homes, farms, businesses such as manufacturing facilities, and public places as opposed to being part of a centralized power plant. These smaller applications range from several hundred watts to multimegawatts. Of the 2012 installations, most of the distributed wind projects consisted of single turbinesthe largest was six turbines. These installations were in 38 states, as well as Puerto Rico and the U.S. Virgin Islands. Iowa led the way, adding 37 MW of distributed wind capacity last year, followed by Massachusetts, which added 27 MW, and California, which added 23 MW. Among the reasons industry leaders gave for the use of distributed wind are a desire to cut utility bills, concerns over future rate increases in gas and coal prices, the availability of state incentives, and the desire to reduce pollution. While it was noted in the 2012 Wind Technologies Market Report that the renewal of the wind energy production tax credit would spur utility-scale development for two or three years, the tax credit is likely to have little impact on distributed wind projects.
Wind power experiences banner year

In August the U.S. Department of Energy (DOE) issued two reports on the state of domestic wind power. The DOE and the Lawrence Berkeley National Laboratory released a report on the state of the U.S. wind market overall. According to the 2012 Wind Technologies Market Report, last year was a banner year for wind energy. More than 13.1 gigawatts (GW) of new wind power capacity was added in the U.S., almost double the added capacity in 2011, bringing total wind power capacity in this country to 60 GW. This makes wind power the largest source of added U.S. electric-generating capacity for 2012, at 43 percent. This exceeds natural gas-generation additions. Much of the increase is attributed to the federal tax credits that had been set to expire at the end of last year and then were extended. It is also attributed to improved cost and performance of wind power. The report also points out that the U.S. installed more wind capacity than any other country last year, resulting
2012 Market Report on Wind Technologies in Distributed Applications

Also in August, the DOE and Pacific Northwest National Laboratory issued the 2012 Market Report on Wind Technologies in Distributed Applications, which shows that the domestic distributed wind energy market grew by 175 MW last year. This puts U.S. wind turbines in distributed applications at 10-year cumulative installed capacity of more than 812 MW from more than
Steelcase installed a counterflow wash system in its finishing pretreatment process that substantially reduced its consumption of water, sewering, energy, and cleaning chemicals.
Steelcase shrinks water, energy, cleaners use in the wash

Counterflow wash system reduces giants environmental footprint, makes deep imprint
Steelcase by the Numbers
1 Rank in global market share 30 Locations globally 101 Years in business 500 Product lines 14000 ISO-certified 80,000 Customers
The Greenquation
As a direct result of implementing a new pretreatment wash system on seven powder coating lines, Steelcase reduced and saved: Energy: 46%; $728,006 Water/Sewer: 54%; $171,338 Process Chemicals: 66%; $41,675 Labor: $113,411 GHG Emissions: 41% Total Cost Savings Annually: $1,054,430
124,000 Employees $2.9 billion Annual sales in 2013 to date

20
By Kate Bachman, Editor
ver the course of its 100-plusyear-old history, the worlds largest office furnishings manufacturer has not only redefined office environments, it has helped to redefine work. Steelcases Grand Rapids, Mich., headquarters is a living laboratory for the development of new concepts for its office seating, tables, storage, spaceseparating screens, desks, walls, and other architectural elements. The manufacturer has undergone a transformation of its own to keep pace with the increasingly mobile and evolving workforce it aims to support and equip. One core value that has remained constant throughout the Fortune 500 companys century-long existence from its inception, however, is its commitment to protecting the environment (Read Steelcase as Environmental Leader at www.greenmanufacturer.net.)
We believe that however small, every action that safeguards and restores the environment is significant. Our vision is to excel in every environmental dimension to protect, replenish, and restore the communities in which we live and serve, said Steelcase CEO James Hackett. As a manifestation of that commitment, the company set goals and devised strategies in 2006 to reduce its overall environmental footprint by its 100-year anniversary in 2012. One area prime for improvement was its energy-, water-, and chemicals-glutting finishing plants where water, chemicals, and energy consumption was high. Mary Ellen Mika, sustainability and energy manager, global procurement, with others at Steelcase, initiated the companys collaborative green partnership with chemicals supplier DuBois (see Figure 1). That supplier relationship led to a systemic revision to the manufacturers finishing pretreatment
Figure 1
Mary Ellen Mika, Steelcases sustainability and energy manager, global procurement, believes that the supply chain ecosystem is a fluid one, and developed a collaborative relationship with a cleaning chemicals supplier that yielded substantial benefits for Steelcase in its finishing pretreatment lines. Metal components going through the pretreatment wash system, shown at left, are cleaned in a counterflow wash system that uses half the water, half the energy, twothirds of the chemicals, and a fourth of the labor that its predecessor did.
process for metal components that significantly reduced its water, energy, and chemicals consumption.
A Pulsating Supply Ecosystem

In any manufacturing ecosystem, suppliers are integral to the success of a company. When a manufacturer is as large as Steelcase, the supply chain is as vital as an artery. That is why Steelcase is very engaged with its suppliers, extending its expertise into their operations and plants along with its expectations for quality, leanness, energy efficiency, cost competitiveness, and environmental stewardship. When Steelcase wanted to green its finishing pretreatment systems at its Kentwood West metals finishing plant
Figure 2
Keith Lane, senior account manager for chemicals supplier DuBois, demonstrated to the finishing group at Steelcase not only how to improve the environmental impact of the cleaning chemicals they supplied, but also the entire wash process.
Figure 3
DuBois introduced phosphate-free, low-temperature cleaning chemicals to Steelcases pretreatment process that reduced its environmental footprint by ridding it of toxins and reducing the amount of energy required to heat the water.
beginning in 2007 as part of its overall environmental strategy, it invited six potential pretreatment chemicals suppliers, including DuBois, to bid on a contract to supply cleaning chemicals. Because manufacturing in an environmentally responsible way was in Steelcases DNA, it was natural that the criteria for the chemicals supplier to win the bid included not only meeting quality and cost standards, but also helping the office furnishings-maker to reduce its environmental impact. Part of that offer to DuBois was a nomination to join the U.S. EPA Green Suppliers Network (see Lean and Green sidebar). The network advises companies on how to wring out energy, material, water, and solid waste in their plants. Steelcase recommended that its supplier consider accessing the networks expertise to apply a lean manufacturing approach to the environmental realm, Mika explained. The idea was that as the customer, knowing what we want and having a lot of experience in finishing operations, we could help provide expertise to as22
sess the suppliers facilities so they could make products better, more costeffectively, and greener for us. How could we directly help our suppliers at their manufacturing locations? How could we work together to achieve that? Mika continued.
Another aspect of the manufacturing giants supplier network is that for a company trying to break into that supply chain, Steelcase is a tough shell to crackit is extremely loyal to its highperforming existing suppliers. As a field manager in this area for 20 years, every time someone said Steelcase, I said, Dont waste your time, because we spent so much time and resources from the 70s to the 90s trying to crack the shell to no avail, said Keith Lane, senior account manager for DuBois (see Figure 2). That was because they are trusting, loyal people, and they had long-term partners already. So when DuBois was invited to submit a bid and nominated to engage in the EPA Green Suppliers Network, Lane wanted to say yes. However, DuBois had already leaned and greened and actually had picked up some knowledge in the field that it could share with Steelcase. At that time, our parent company was as far down that path as Steelcase was. I was getting some resistance. I was going to our people and saying, Lets do this, and they were saying, Weve done all that, Lane said.
Pretreatment Washer - Former

City water Processed RO waterVirgin arch, counterflow makeup Process makeup (as needed) from pressure side of pump Counterflow makeupfed as neededto chemical stage(s) Process flow to drain
Storage Virgin Arches
City Water AG Filter Carbon Soften RO Unit
Stg 1
Chemical
Stg 2
Chemical
Stg 3
Rinse
Drain
Stg 4
Chemical Sealer
Drain
Stg 5
Recirc RO
Drain Drain
cleaner/phos
cleaner/phos
Drain
Drain
Figure 4
Previously, fresh water was fed into every stage of the wash system and water flowed to the drain at every stage as well. An enormous amount of water and cleaning chemicals were wasted this way, as well as the energy to heat the water.
Operators test samples each shift from the four tanks in the washer system in this titration station to make sure the chemical concentrations, pH, temperatures, and spray pressures in the nozzles are correct.
Metal components are pretreated and powder-coated on the same line.
We were not thinking that this philosophy could be applied in reverse, Mika said. In fact, the patient became the doctor. Ultimately that is the essence of the supply chain partnership and cooperation. How can we best access each others skills and expertise to make improvements? Mika added.
Greening the Wash System Beyond Cleaners

Lane knew that bringing something extra to the table could only improve DuBois chances of winning the bid and nurturing the coveted supplier relationship. Rather than submit a bid based on price per pound, Lane and his group offered to show Mika and the finishing and supply chain groups at Steelcase not only how to improve the environmental impact of the cleaning chemicals they supplied, but also the entire wash process. DuBois wanted to take a total cost/lean and green approach. Rather than give us a material price, they asked for a demonstration opportunity on our line, Mika said. After much internal deliberation and concern about possible adverse effects on product quality, Steelcase granted DuBois a six-week trial.
Steel components are in the queue to enter the finishing lines on which they will be pretreated and then powder-coated.
less heated water is going to drain, so we arent losing all that energy anymore.
Mary Ellen Mika, Steelcase
First, the cleaners supplier introduced low-temperature, nonphosphate chemicals to Steelcases pretreatment processand then went a step further (see Figure 3).
We got to week two into the six-week trial and then really started pushing hard, Lane said. We said, While were in the washer, please let us show you another approach. The other approach Lane proposed to the Steelcase group was a cascading, or counterflow, wash system to reduce water, sewering, energy-and even the amount of cleaning chemicals needed. The latter effort might seem counterintuitivea supplier wants to sell more product, not lessbut metabolizing Steelcases environmental footprint reduction effort helped secure DuBois supplier relationship, which, in turn, helped the chemicals company sell more product in the long run. That cant be overemphasized, Lane said. We found ourselves speaking the same language.
How the Counterflow Wash System Works

The line on which DuBois demonstrated its system was Steelcases Kentwood West Line 3-4, on which it manufactures its
Figure 5
Steelcases Mike Warners explains how the water flows in reverse order in the counterflow wash process from the last stage to the first stage.
large case storage product line. Before the steel and aluminum components head to the powder-coat process, they first must go through a five-stage pretreatment wash line. The five-stage washer has one prewash and only one chemical cleaner stage. The prewash gets chemicals and heat from the carryover from the cleaner stage into the rinse stage and back through the counterflow system. There are three rinse stages total. The manufacturer had been feeding fresh water to all three rinse stages and draining water at every stage (see Figure 4). They were making reverse osmosis [RO] water and using it in a halo at the end of the washer and in stage five. Then that water was going to the drain. The rest of these stages were made up of fresh city water, Lane said.
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Lane recommended that they switch from a system that sourced fresh water and sewered water to drain at each stage to a counterflow wash system that feeds fresh water to only one rinse stagethe final oneand filters and reflows the water from the last rinse stage to the first one. In the new counterflow system, while parts travel in one direction from stage 1 to stage 5, water flows in the opposite direction, from stage 5 to stage 1. Steelcase Finishing Engineer Mike Warners explained how the water flows in the finishing pretreatment process (see Figure 5). We take the virgin water at stage 5 and instead of overflowing it to the drain, we run it into an overflow trough and it gets pumped back to stage 4; then it runs over from stage 4 and gets pumped back to stage 3; at stage 2, the heated chemical stage, process makeup water is taken as needed from the pressure side of the pump. Counterflow water from stage 3 is pumped to stage 1, the prerinse stage, and that overflow is the only water that goes to the drain. (See Figure 6.) Stage 1 is a prewash station that removes much of the oil from the fabricated metal. Water is sourced from the stage 3 overflow tank. Whatever excess water is remaining from this first stage goes to the drainin fact, this is the only point in the whole washer system where water drains.
Theres discharge there, but were continuing to clean the process as we use it. We like to think that were matching the demand with chemical additions and match the soil loading with this overflow and depletion. Over the course of the life of the tanks and process, things stay much better, Warners said. Stage 2 is a cleaner chemical stage. One of the changes to the cleaning system is that the cleaning chemicals are low-tempdesigned to run at lower temperatures. Now the tank is heated to 100 degrees, which is much lower than the 120 to 135 degrees it was heated to previously. This change came about when Steelcase converted from a liquid-based paint to a powder coating process. Water is sourced from the stage 3 circulation pumps as detected by a level sensor. Stage 3 is an ambient-temperature, clean-water rinse. No cleaning chemicals are added in this stage. Heat and cleaning chemicals are transferred from stage 2 as components are rinsed off into this tank. Water is pumped from stage 4 overflow. Stage 4 is a second ambient-temp rinse stage. Water is pumped from overflow water sourced from stage 5. Stage 5, the RO stage, is very pure water. A rinse aid is pumped from a drum into the water in this stage to
Ultimately that is the essence of the supply chain partnership and cooperation. How can we best access each others skills and expertise to make improvements? Mary Ellen Mika, Steelcase
This cascading approach helps us get rid of soils on a gradual, consistent basis instead of as a big dump. We can keep each stage a lot cleaner by doing it gradually and consistently, Warners said. help drain water from the parts before they are dried. The company installed a Siemens Industry Water Division RO system because sourcing the purer, virtually minerals-free water dramatically reduces the limescale accumulation,
Pretreatment Washer - Current
City water Processed RO waterVirgin arch, counterflow makeup Process makeup (as needed) from pressure side of pump Counterflow makeupfed as neededto chemical stage(s) Process flow to drain or recycle
City Water AG Filter Carbon Soften RO Unit
Virgin Arches
Stg 1
Prerinse
Drain
Stg 2
Chemical
Drain
Stg 3
Rinse
Drain
Stg 4
Rinse
Drain
Stg 5
Recirc RO
Drain Drain
Figure 6
Clean, reverse osmosis-purified water enters stage 5. It runs into an overflow trough and is pumped backward to the stage 4 rinse tank and then to the stage 3 rinse tank. That overflow is then pumped to the stage 1 prerinse tank. The rinse water that is pumped to stage 1 is the only water that goes to the drain. Energy-efficient Baldor motors pump the water from stage to stage.
which, in turn, greatly reduces the labor associated with removing it. This is the only stage in the washer at which any water enters the process (at a rate of 3 to 4 GPM). As a result, we have one process input and one output. We reserve the purest water for the final rinse stage, Warners said. So, in the new version, there are only two points where water goes to the drain, Mika added. The water for stage 5 is processed through RO, so some of the water from that process goes to drain and water from the first washer goes down the drain. In the past, all of the water from those stations went to drain.
why the mapping was necessary. If you dont map that part of the process, you cant ask, Could we turn a stage off? Can we combine two chemical stages? It all starts with understanding the system in terms of time.
Storage
Water remaining from the first stage goes to drainin fact, this is the only point in the whole washer system that wastewater does.
DuBois developed a spreadsheet to calculate optimal contact time and wash durations using actual measurements of the stations. We literally got inside the washer and measured how long each section was, from the first riser of the first stage to the end. They entered the dimensions and line speeds into a spreadsheet, and used a formula to
convert it to determine how much time, in seconds, the component needed to stay in any given stage. For example, in one 12.9-ft. section, traveling at 18 feet per minute (FPM), the component needed to stay in the stage for 43 seconds. While we were doing this, we were also mapping the flow through the process for the water, Lane said.
Global Environmental Gains, Cost Savings

Steelcase realized energy savings both from using low-temperature cleaners and reducing the amount of water that needed to be heated. The less water you use, the less energy you need to pump and heat the water for the process. Conversely, the more water you flood to the drain, the more energy you consume to heat the incoming water supply, Mika said. Process improvements were realized as well. I really cant emphasize
Priming the System Timing

The timing of each of the five wash stages had to be mapped out so that the components are washed sufficiently but without wasting water, chemicals, and energy. Warners gave another reason
enough how significant the process control we gained is by having one input and one output instead of four or five inputs and three or four outputs, Warners said. Mika said the new wash system hugely contributed to helping the company achieve its environmental footprint re-
duction goals. What we ended up seeing as a result of this change on the first wash line was significant. In only one quarter in 2006, this process brought about a 15-million-gallon reduction. Less water is being wasted by going to drain. Because of that, less heated water is going to drain, so all that energy
Lean and Green

The Green Suppliers Network is a collaborative venture among industry, the U.S. Environmental Protection Agency, and the U.S. Department of Commerces National Institute of Standards and Technologys Manufacturing Extension Partnership (NIST MEP). The network works with large manufacturers to engage their small and medium-sized suppliers in low-cost technical reviews that focus on process improvements and waste minimization. The assessments are designed to help supplier manufacturers increase energy efficiency; identify cost-saving opportunities; and optimize resources to eliminate waste to reduce their environmental impact, improve the efficiency of their processes, and increase profits.
Steelcases global headquarters in Grand Rapids, Mich., is a living laboratory for the development of new concepts that keep pace with todays mobile and evolving workforce.
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that we were losing before, we arent losing anymore, she continued. Plus, because we began using low-temperature cleaners, we didnt need to heat the water to as high a temperature, saving even more BTUs. As a result of implementing the new wash system on six additional powdercoating lines, Steelcase reduced its water consumption globally by more than 45 million gallons per year. The company saved $728,006 in energy, $113,411 in labor*, $171,338 in water/sewer costs, and $41,675 in process chemicals for a total of $1,054,430. We are saving $1 million per year in energy, water, labor, and chemicals as a result of the improved pretreatment system, Mika said. The new wash system is a huge advantage for Steelcase, Warners added.
The project had a happy ending for DuBois as well. After that rst successful project, DuBois was awarded many more projects in other wash lines, ultimately becoming Steelcases sole pretreatment chemical supplier. *Labor cost reductions were a result of using the RO water system, which removes minerals that otherwise build up as limescale that must be removed.
Photography by Craig van der Lende Editor Kate Bachman can be reached at kateb@greenmanufacturer.net. DuBois, 3630 E. Kemper Road, Sharonville, OH 45241, 800-438-2647, keith.lane@ duboischemicals.com, www.duboischemi cals.com Steelcase, 901 44th St. S.E., Grand Rapids, MI 49508, 616-247-2710, www.steelcase. com
For more information on how Steelcase reduced its environmental footprint in its nishing lines and achieved Leadership in Energy and Environmental Design (LEED) certication in its Wood Finishing plant, read: First to LEED; VOC-less nish, www.greenmanufacturer.net. For more information on how to reduce water consumption, read: How 5 manufacturers reduce water use, http://www.greenmanufacturer. net/article/machinery-and-equipment/ how-5-manufacturers-reduce-water-use Water reuse, recycling, conservation in manufacturing, http://www.green manufacturer.net/article/facilities/ water-reuse-recycling-conservation-inmanufacturing
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Greenquation
Lighting and Controls Retrot: Annual 700,000 kWh saved = $60,000 Total project cost = $188,178 Utility incentives paid = $48,967 ROI with AEP Ohio incentive = 2.4 years ROI without AEP Ohio incentive = 3.2 years
ehold the White Castle slider. The moist, steam-grilled, slender, uniquely textured, 2-in. by 2-in., 2-ounce 100 percent beef burger rests unapologetically on a soft, square bun, topped with tasty xins, and slides into an open-top box. It is the inspiration for eating competitions and the object of late-night cravings. (Think Harold & Kumar Go to White Castle.) The square burgers in their square buns are served out of white turreted buildings sided with square building panels that mirror the squareness of the burgers. Porcelain Steel Buildings Co., in Columbus, Ohio, originally made porcelain steel tiles and now manufactures White Castles xtures and cooking equipment. The manufacturers 700,000-kWh, $60,000 annual savings that resulted from a lighting retrot was a tantalizing treat that slid down easy.
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Manufacturing an Icon
White Castle first developed its patented building designa castle motif framed with cold-rolled steel channels holding white porcelain panelsfor a Chicago restaurant in the 1930s (see lead photo). The concept ultimately led to the development of White Castles metal fabrication division, Porcelain Steel Buildings Co., or PSB, in Columbus, Ohio. By 1934 all of the building materials were fabricated by PSB, as well as all of the stainless steel fixtures and cooking equipment used in White Castle restaurants. Today the company no longer makes the building materials,
but it continues to manufacture all of the restaurants stainless steel fixtures and equipment (see Figure 1). PSB also has fabrication contracts in other sectors, including automotive and agriculture. PSB sits on the companys 10-acre campus in a 107,000-sq.-ft. building White Castle has owned since 1934. It houses mechanical stamping presses, shears, plasma and laser cutting machines, press brakes, welding booths, grinding, and powder coating lines.
Lighting
The overarching goal for White Castle and PSB was to achieve uniformity in light levels throughout the facility for PSBs 50-plus employees. The uneven light levels created challenges, such as the need for welders to work using flashlights. A simple lighting retrofit would not address all of the issues we had in our facility, said John Wheeler, building maintenance supervisor. We needed to address the dim lighting and patchwork lighting issues throughout. The company hired local electric contractor Loeb Electric to retrofit the plants lighting and to install a lighting controls system. Loebs team crafted a plan that puts the right amount of light in all workspaces and saves electricity. After analyzing the facilitys lighting systems, Loeb installed 4-foot, 28-watt T8 linear fluorescent lamps to replace a patchwork of lamp types that created uneven lighting conditions. In addition, the electric contractor installed occupancy sensors, photocells, low-voltage switching overrides, and energy-efficient timers. Using sensors, the system supplies lighting in spaces based on occupancy and lighting conditions. It wired the lighting into a low-voltage panel to further reduce energy consumption in the PSB facility (see Figure 3). The company wanted to reduce the amount of electricity used while still providing the right amount of light for its working team members, according to Wheeler.
Legacy of Green in White

Long before being green was cool, White Castle System was reusing its bun boxes, sending them from its bakeries to its restaurants and back again and again until they could no longer be used, and then recycling them at the end of their useful lives. This practice began 70 years ago, when the cost of the iconic slider was just 5 cents. Since then the company has continued its environmentally friendly practices, the latest of which was to install a lighting retrofit, complete with occupancy sensors, in its PSB plant (see Figure 2). Energy efficiency makes sense for our company. It makes sense economically and it goes along with what has been a part of White Castles DNA since the very beginning, said Environmental Engineer Jeff Miller. We have never been a company that green washes its reputation to be something we are not. We practice what we preachin our bakeries, at our restaurants, and in all of our facilities. As a result of the lighting and controls retrofit, White Castle is saving over 700,000 kilowatt-hours (kWh) annually at PSB, which amounts to approximately $60,000 on its electric bill yearly. The manufacturer is likely to continue to realize the full effects of the lighting control system years after its installation.
Above Left: Behold the slider, a White Castle staple. Above: White Castle System Inc. developed its patented building design of a one-story castle motif framed with coldrolled steel channels holding white porcelain panels in the 1930s. The concept ultimately led to the development of White Castles metal fabrication division, Porcelain Steel Buildings Co., or PSB, in Columbus, Ohio, which now manufactures its fixtures and cooking equipment similar to those shown in this historic photo, as well as products for many other industries.
Utility Incentives Sweeten the ROI

White Castle is a big company with plenty of internal competition for investment dollars. A specific protocol must be followed to get approval for investments such as the lighting retrofit. Wheeler, himself an electrical contractor for 20 years, drew on his experience and developed a well-thought-out plan,
Figure 3 Figure 1
PSB continues to manufacture all of White Castles stainless steel fixtures and equipment used in the restaurants. The lighting control system is wired into a low-voltage panel.
Figure 2
Bright, evenly distributed light on the PSB shop floor has improved working conditions and safety while saving the company thousands of dollars per year.
which he presented to Director of Construction & Corporate Facilities Craig Martin, who then took it to the companys Capital Expenditure Committee. The regional utility company, AEP Ohio, offered incentives that helped
30
White Castle make the decision to invest in improving its lighting. Johns [Wheelers] understanding of what needed to be done and AEP Ohios incentives made our internal decision process much easier, Martin said.
The incentives also allowed us to do more of the lighting work than we first thought we could do. Wheeler can now monitor the buildings lighting system and troubleshoot from his laptop computer wherever he and his computer may be. He can tell if lights are on in an unused area of the facility or if lights have failed to come on at the right time in an area while team members are working. Social Responsibility and Environmental Sustainability Manager Shannon Tolliveralso great-granddaughter of White Castle founder Edgar (Billy) Ingramprovided a historical perspective about the lighting retrofit: Our corporate responsibility policy touches on every aspect of what we do. Yes, we may decrease our costs. But by saving electricity or recycling bun boxes, we are taking a big picture, long-term view of our sustainability. She added, That is how White Castle has built its heritage over 90 years.
AEP Ohio, a unit of American Electric Power Co. Inc., www.aepohio.com Porcelain Steel Buildings Co., 555 W. Goodale St., Columbus, OH 43215, 614-2285781, www.psbcompany.com
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cool workers; cut drying time

After stone veneer panel manufacturer Stone Panels, Coppell, Texas, installed HVLS fans to keep employees comfortable and regulate the facilitys temperature year-round from floor to ceiling, it discovered another benefit. The airflow reduced process drying time from seven days to two.
Texas plants fans

With a long-standing history spanning many decades and multiple continents, Stone Panels recently relocated all of its operations and manufacturing to Texas. Every step of the companys manufacturing process occurs in the 166,000-square-foot facility, from receiving raw materials to shipping finished goods to customers around the world. The plants design incorporates multiple areas and workstations, each dedicated to a specific step in the manufacturing process. The building is not equipped with a centralized air-conditioning system. Company management recognized that working in the humid, dusty facility would make employees very uncom-
ocated in the heart of Coppell, Texas, just outside of Dallas, Stone Panels Inc. manufactures one-of-a-kind, lightweight stone veneer panels to be installed in building facades. The companys StoneLight panels are used in new construction and renovations in homes, schools, airports, and commercial and government buildings all over the world (see Figure 1).
34
fortable without a means to keep them cool. Seeing as were in the middle of Texas, it gets extremely hot and humid! Today its 105 degrees, said Dewey Winker, plant manager. Winker knew that employee discomfort leads to a drop in productivity. Without having a centralized cooling system available to our employees, the midday heat of the Texas summers can really bring work to a halt, he said. The nature of the products manufacturing requires long lead-times, generally, so additional delays are devastating to order processing and profitability. Our employees are such great assets and needed during every step of the manufacturing process to bring
Figure 1
Stone Panels facade panels are installed in homes, schools, airports, and commercial buildings all over the world, including (from left to right) the Nesbett Courthouse in Anchorage, Alaska; the Shawnee Mission Hospital, Shawnee Mission, Kan.; and the Barclay Towerm New York, N.Y.
quality products to our customers, Winker said. So keeping them cool, comfortable, and productive is a top priority.
Installed HVLS Fans

It was this need to keep employees cool that ultimately prompted Winker to look into installing high-volume, lowspeed (HVLS) fans throughout the facility to reduce the temperature and the humidity. Working with his local Kelley distributor, Miner North Texas, Winker opted to install six 24-foot FUSION HVLS fans throughout the plant. They are really impressive with the amount of air they move to keep the facility cool, Winker said. They made a huge difference, a noticeable differencebetween 10 to 15 degrees. The fan is designed to create a comfortable environment while maintaining an energy-efficient facility. Although the single-piece anodized aluminum fan blades are lightweight, the fan blows a column of air down toward the floor and outward in all directions before it is pulled back vertically toward the blades to create what is known as a horizontal floor jet. It is this floor jet that produces the circulation (see Figure 2).
The air circulation causes the air to feel cooler than it actually is as the breeze passes over the skin. The slowmoving breeze at 2 to 3 MPH can reduce perceived temperature by an equivalent of 7 to 11 degrees F. Since we installed the fans, we have a much cooler and less humid work environment. We
have seen lead-times decrease as a result of employees comfort levels having improved so dramatically, Winker added. The fans airflow also eliminates warm or cold air pockets throughout the warehouse for more consistent cooling and energy efficiency.
Figure 2
The patented blades on the Kelley FUSION HVLS fan produce a large cylindrical column of air that flows down to the floor and outward in all directions. This horizontal floor jet pushes air farther before it begins to move up vertically and is drawn back through the fan. In cool seasons, the large fan can operate in reverse, circulating hot air trapped at the ceiling level.
Unexpected Double Benefit: Reduced Dry Time

Once installed, the fans provided an additional process advantage. And little did we know they would end up providing a surprise benefit to our manufacturing process that would increase our capacity and reduce our lead-time, Winker said.
After we put the fans in, we couldnt believe the difference the downward airflow made to cut down cure times.
Dewey Winker, Stone Panels
While employee safety, comfort, and productivity are always top priorities at Stone Panels, so is an efficient manufacturing process. The manufacturer uses a state-of-the-art diamond tip process that requires multiple steps to cut the stones, polish, and create the pan-
els and then add a finish to seal them for protection from the elements. The drying time during the final stage took the longest. In the winter, it would take a week to 10 days to dry, depending on the moisture level or the humidity, Winker said. During the summer we were taking the product outside to dry. Well, if we left it outside overnight and it happened to rain, it completely ruined our production plans for the following day. We pride ourselves on providing our customers only the highest-quality building products, and if that means a longer lead-time, we dont mind. But after we put the fans in, we couldnt believe the difference the downward airflow made to cut down cure times, Winker said. The airflow the six fans create has reduced the drying time to two days. So now we leave all of the material inside in the summer. So during the summer its a benefit, but during the winter its a huge benefit, Winker added.
Stone Panels, 100 S. Royal Lane, Coppell, TX 75019, 800-328-6275, http://stonepanels.com Kelley Co., USA & International, 1612 Hutton Drive, Ste. 140, Carrollton, TX 75006, 972-466-0707, sales@kelleycompany.com, http://kelley.4frontes.com
For more information, go to www.greenmanufacturer.net:

Improving industrial environments with HVLS fans, www.greenmanufacturer. net/article/facilities/improving-industrial environments-with-hvls-fans Improved air circulation cuts heating bill at lubricant plant, www.green manufacturer.net/article/big-ass-fans/ plant-applications-improved-air circulation-cuts-heating--bill-at-lubricant plant 8 ways to rock the dock, www.green manufacturer.net/article/facilities/ 8-ways-to-rock-the-dock-
NOV. 6, 2013
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Control scale
to optimize HVAC equipment energy efciency

Get water-fed HVAC equipment up and running smoothly with electronic descaling
By Jan de Baat Doelman

t costs U.S. industry billions of dollars a year to control and remove the limescale that builds up in water-fed industrial heating, venting, and air-conditioning (HVAC) equipment such as boilers, chillers, heat exchangers, and evaporative coolers. Limescale not only increases downtime and maintenance costs and causes the early replacement of capital equipment, it also increases energy consumption. Descaling can minimize problems related to limescale accumulation on HVAC equipment by conserving water, reducing energy, and minimizing unexpected production shutdowns. Electromagnetic descaling devices are environmentally friendly alternatives to chemical and mechanical descaling.
Heat exchangers that have become fouled with limescale deposition lose their effectiveness and require much more intensive energy consumption to operate.
Glossary
Fouling: The unwanted deposition and accumulation of materials, including limescale, on heat transfer surfaces. Ion Exchange: A reversible reaction between ions that are stored in a solid ion exchanger and the ions of a medium pass through it. Used also in water softeners, where Na-ions from the exchanger substitute for Ca-ions from the passing water. Pipeline Pigging: Undertaking pipeline inspection, maintenance, and cleaning with a cylindrical-shaped device which is pushed through the pipe by water pressure or pulled through the pipe. Nucleation: The initial process that occurs in the formation of a crystal from a solution, a liquid, or a vapor, in which a small number of ions, atoms, or molecules become arranged in a pattern characteristic of a crystalline solid, forming a site upon which additional particles are deposited as the crystal grows. Law of Mass Action: The rate of a chemical reaction is directly proportional to the molecular concentrations of the reacting substances. Idiomorphic: A substance that crystallizes in a shape that is genuine and not disturbed by other substances.
38
Scale Deposition Types

Scale usually refers to a mixture of sparingly soluble mineral salts. Mineral scale deposition, or fouling, occurs during heat transfer or pressure changes. Calcium carbonate (CaCO3) scaling from hard water, as well as calcium phosphate and oxalate formation in sugar reneries, are examples.
Other types of scale include the growth of algae and bacteria (biofouling), the consolidation of loose particles (particulate fouling), the accumulation of coke-like deposits (for example, chemical reaction fouling) (see Common Fouling Mechanisms sidebar), and sometimes a combination of several different materials. Over time they create changes to the water composition.
How Scale Increases Energy Use

CaCO3 is the predominant component of the hard and tenacious scale deposit from water and is particularly present in processes involving heat transfer. A concentration of dissolved solids by repeated partial evaporation of the water is the main factor that causes calcium carbonate scale. Eventually even soft water will become scale-forming when minerals are present in low concentrations.
Process, maintenance, and facility managers should be concerned about scale deposition. Deposits become an insulating layer on heat transfer surfaces that inhibits efficient heat transfer. This causes more power consumption. It is estimated that 40 percent more energy is needed to heat water in a system fouled with inch of limescale. Often manufacturers install heavyduty, expensive heat exchangers to compensate. Scaled boiler tubes mechanically fail as a result of overheating. Cooling tower plates can collapse under the weight of scale deposits. Scale particles breaking loose and subsequently impinging upon other surfaces can erode the surfaces. Scale in pipe work reduces the available cross-sectional inside diameter (ID) and therefore the flow resistance (see Figure 1). To maintain throughput
volumes through this narrower ID, a larger, more powerfuland power-consumingpump will be required, but this may help only temporarily. It costs money to shut down a plant for cleaning.
Other Ill Effects of Scale

At first the formation of a thin, uniform layer of scale or wax temporarily reduces steel corrosion, but eventually stagnant conditions develop under the deposit and electrochemical reactions corrode the steel surfaces. This results in fluid leaks and equipment failure. In the food and beverage industry, even the undesirable trace particulates in the piping can contaminate the product and foul the flavors and alter the colors, making the product unsalable. Oil wells have significant scaling problems from the highly mineralized water that is extracted with the oil. Not only are plant and product integrity at risk; personnel health and safety may be compromised. Safety valves or emergency process sensors that are fouled may not operate in an emergency. Overheated boilers have been known to explode. Failure to control bacterial growth in cooling water can create conditions hazardous to health (for example, production of Legionella or pneumophila) or, in anaerobic conditions, may allow the production of toxic hydrogen sulfide from sulfate-reducing bacteria.
Recognizing Fouling
Because scales and other deposits generally form inside closed systems, it is not always evident that deposition is occurring. But some clues can provide the necessary evidence. It is useful to try to answer the following questions: Are energy and heating bills lower immediately after cleaning the plant? Is it necessary to arrange significant planned and unplanned downtime? Are heat exchangers performing below design? Is corrosion a problem in the plant?
Figure 1
Scale in pipe work reduces the available cross-sectional inside diameter (ID) and the flow resistance, requiring more power to propel the fluid.
Are there signs of unexpected deposit formation within the system? The more times the answer is yes, the more likely it is that scaling or fouling is occurring. Controlling deposition will save energy, prevent equipment failure, and reduce maintenance. Furthermore, a successful treatment strategy maintains uid ow, reduces corrosion effects, and provides a safer environmentall of which save money.
Magnetic Field
Particles and dissolved minerals with positive and negative charges
Electric Field
Water less saturated with mineral ions, now capable of dissolving existing scale layers
Solving the Problem

A process audit identies the extent of the current problem; the point in the system corresponding to initial fouling; and, most useful, why there is a problem. From the evidence collected, it may be possible to nd a solution without the need for expensive external control measures. Minor changes in the process temperature, pressure, pH, or uids composition could signicantly reduce the fouling potential at practically no cost. Treatment options include inhibitor chemicals, descalers, ion exchange, physical cleaning such as pipeline pigging, and the installation of electromagnetic devices. Although it is usually possible to nd a chemical solution to a fouling problem, ever-increasing environmental and safety pressures demand that chemical
Figure 2
Electromagnetic scale removal devices work by producing a complex frequencymodulated waveform, inducing an electromagnetic eld inside the pipe. Scientic research shows that a specic electromagnetic eld initiates a colloidal cluster regrouping in the rst stage of crystallization. The resulting CaCO2 will be in the form of scattered particles that will be ushed out by the medium.
consumption be reduced wherever possible. Increasingly, restrictions are being applied regarding the use of chemicals because of their environmental impact. Physical Mechanical Methods. A range of physical methods can be used to remove fouling deposits. Water jetting or sand and plastic-bead blasting can be used in accessible locations. Such methods, however, can cause abrasions on the surfaces, which in turn can
lead to an increase in scaling because the abrasions provide a suitable platform for concentrated limescale. Physical Electromagnetic Method. Electromagnetic scale removal devices alter the shape of the CaCO3 crystals to reduce the adherence and deposit buildup on the pipe wall by changing nucleation in such a way that the particles do not stick to any surface (see Figure 2). These devices can affect descaling
Common Fouling Mechanisms

The common fouling mechanisms are: Particulate fouling - Resulting from sediment of dust, rust, ne solids, and other entrained solids. Crystallization fouling - Calcium carbonate is the predominant component of the hard and tenacious scale deposit from water and is particularly apparent in processes involving heat transfer. A concentration of dissolved solids by repeated partial evaporation of the water is the main factor that causes calcium carbonate scale. Even soft water will eventually become scale-forming when concentrated numerous times, i.e., two, three, four, or even more. Biological fouling - Occurs when biological organisms grown on heat exchanger surfaces. Problems arise from algae to other microbes such as barnacles and zebra mussels. At certain times of the year when microbes are said to bloom, colonies several inches thick may grow across the heat exchanger service, affecting thermal performance. Chemical reaction fouling - This type of fouling occurs when the depositions are formed as a result of chemical reaction. Corrosion fouling - Results from a chemical reaction that involves the heat exchanger surface material.
40
green MANUFACTURER September/October 2013 www.greenmanufacturer.net
downstream of the point of installation. A softening and loosening of existing scale several weeks after installation is commonly reported. This treatment is effective when the water flow is extremely low or zero, as the term qE is independent of the flow velocity. Because scale no longer builds up, the flowing water will remove existing layers of scale over time, caused by diffusion according to the law of mass action. By electromagnetic treatment, hard water is capable of dissolving and removing existing scale layers. The direct effect of an electronic device described above is on the nucleation process and colloids. This approach operates on a phenomenon known as the Lorenz force. F = qE + q (V x B) Where F is excited by charged particles that flow through a field q = Charge on the particle E = Electric field vector V = Particle velocity vector B = Magnetic field vector Electromagnetic devices operate at very weak alternating electromagnetic fields, where not so much the strength is important; rather, the frequencies used determine a successful treatment. Scale prevention and removal are achieved in several ways: 1. Electromagnetic devices influence the initial nucleation, resulting in crystals that do not stick together. While untreated water builds up matted structures that grow more and more, electromagnetic treatment creates idiomorphic, scattered crystals that will not form matted structures. They have a roundish shape, which means that they have a rather big volume in relation to a rather small surface. This feature makes them sensitive to water currents and they will be flushed out of the pipe easily. 2. Colloidal clusters in water may have positive and negative charges (Janus model) at different places. Only a
little energy is needed to reposition the colloids if an electromagnetic field with the correct frequency is used. Once these colloids have been repositioned, their tendency to stick is much lower. 3. The scale on a pipe wall acts like any process at a junction of two substances; the law of mass action applies. This means that there is an action and a reverse action simultaneously. In this case, while some particles build up scale, other particles will go into solution again. In untreated water, the tendency for particles to build up scale is stronger than to dissolve. After treatment, the situation changes: As the particles in water stop depositing, scale particles dissolve.
40 percent more energy is needed to heat water in a system fouled with inch of limescale.
Besides the chemical law of mass action, there is a physical aspect that supports scale removal. Scale builds up layer by layer, piling up more and more. These layers, however, reflect changing water composition over time. So while they are quite homogenous in the layer itself, the surrounding layers have a different composition. The interlayer bonding force between the layers is weaker than inside a layer. The last layer, being in contact with the water, will be attacked first by the treatment. When it is removed, the intermediate layer will be removed quickly, exposing the next inner layer. Layers differ in composition and thickness, which determines the time it will take to remove them.
Jan de Baat Doelman is president, Scalewatcher North America Inc., 345 Lincoln St., Oxford, PA 19363, 610-932-6888, sales@ scalewatcher.com, www.scalewatcher.com.
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Steal Shamelessly
This past June I attended our Zero-Waste-toLandll Workshop and had the opportunity to hear David Parish, senior vice president of operations and purchasing for Allison Transmission, speak about his goals and vision for their sustainability efforts. During his talk, one of the things David said struck me as very odd. He said when it comes to making your company more sustainable, you should steal shamelessly. Say what? Did I hear that correctly? Perhaps some context can clear this up. David didnt mean to physically steal something, although I have to admit that was the rst thought that went through my head. David was referring to benchmarking the green practices, ideas, and methods of others. The more you think about this statement, the more I think you will agree that he is absolutely right! Making our operations more sustainable can not only have a positive impact on the bottom
By Aaron Mason, Vice Chair, Green Manufacturer Network line, but it also improves the environment for all of us. So, really, we are all in this together. If you still cant get over this phrase, dont think of it as stealing, think of it as trading, exchanging, or practice-sharing. Trading shamelessly sounds a little better and actually might be closer to reality, because unless you are brand-spanking new at this, you likely have ideas to share as well. The next time you borrow a sustainable idea and feel like clearing your conscience, consider giving another idea back to the industry or your local community. How do you nd like-minded people who are interested in sustainable manufacturing? Join the Green Manufacturer Network (GMN) and consider participating in events like our upcoming Energy Efciency Workshop on Nov. 6 in Lafayette, Ind., where youll see an auto manufacturers energy-savvy operations in action (visit greenmanufacturer.net/ee for details). In a nutshell, GMN is all about helping you steal ideas not only very shamelessly, but also very easily. We are building a knowledge base and group of contacts in sustainable manufacturing that is second to none. Ill get off my soapbox now and leave you with one nal thought. The next time your boss asks you how its going, tell him or her you are stealing shamelessly. Youre either going to get a thumbs-up or an odd, suspicious look. Either way, its a conversation starter that can get your management engaged in sustainable manufacturing. Aaron Mason is the vice chair of the Green Manufacturer Network Advisory Board and director of operations for Hawkeye Energy Solutions, an organization dedicated to energy savings through the use of energy management, energy monitoring, and building systems that empower corporations with real-time energy and utility data: 1006 Geneva St., Shorewood, IL 60404, 815-744-0505, www.hawkeye-es.com.
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43
Material Handling Directory: Reusable Pallets

Company
Ameripac Industries Advantage Plastics of New York All Service All Packaging Inc. (ASAP) BASCO Inc. Beacon Industries Inc. Beck Packaging Corp. BGR Inc. Boomerang Products Inc. Bridge Packaging LLC
Location
Erie, PA Winter Haven, FL Greenacres, WA University Park, IL Saint Louis, MO Allentown, PA West Chester, OH Placentia, CA Fort Wayne, IN Milwaukee, WI Land O Lakes, FL Lynwood, CA Pittsburgh, PA Hartford, CT Elk Grove Village, IL Leetsdale, PA Toledo, OH Greenville, SC Peterborough, ON, Canada Philadelphia, PA Huntingburg, IN Lisle, IL West Chicago, IL Quincy, IL Middletown, OH Kent, WA
Website
www.ameripac.net www.advplasticsny.com www.asappallets.com www.bascousa.com www.beacontechnology.com www.beckpackaging.com www.bgrinc.com www.boomerangproducts.com www.bridgepackaging.com www.browncor.com www.busingco.com www.centurypallets.com www.chamberspackagingconnection.com www.champlincompany.com www.plasticpallet.com www.cratersinc.com www.4mailers.com www.del-tec.com www.enviro-pack.biz www.fpwoll.com www.fibertechinc.net www.freundcontainer.com www.glpackaging.com www.greenlinearmor.com www.grangerplastics.com www.harrisonequipment.com
BrownCor Busing Co. Inc. Century Pallets Chambers Packaging Connection
Champlin-Packrite Cherrys Industrial Equipment Corp. Craters Inc. Cutting Edge Converted Products Inc. Del-Tec Packaging Inc. Enviro-Pack Material Handling Inc. F. P. Woll & Co. Fibertech Inc. Freund Container & Supply/ A Division of Berlin Packaging GL Packaging Products Green Line Armor The Granger Plastics Co. Harrison Equipment Co. Inc.
Copyright 2013 by FMA Communications Inc. Reproduction in full or in part without written permission of the publisher is prohibited.
44
Company
J.H. Nunn Associates Jeco Plastic Products Inc. Larsen Packaging Products Inc.
Location
Rolling Hills, CA Plainfield, IN Glendale Heights, IL Vienna, OH Rockledge, FL Marietta, OH Jacksonville, FL Vienna, OH Beamsville, ON, Canada Oconomowoc, WI Pasadena, TX Bayonne, NJ Somerville, NJ Medford, NJ Harborcreek, PA Janesville, WI Madeira Beach, FL Skokie, IL Sterling Heights, MI Cincinnati, OH Indianapolis, IN Wilkes Barre, PA Broken Arrow, OK Liberty Center, OH Dale, IN Lake Forest, IL
Website
www.jhnunn.com www.jecoplastics.com www.larsenpackaging.com www.litco.com www.lrmind.com www.mar-pak.com www.mdcpackaging.com www.millwoodinc.com www.niagarapallet.ca www.orbiscorporation.com www.pasadenapallet.com www.pdqplastics.com www.polycel.com www.prostackpallets.com www.porterie.com www.randmh.com www.reusabletranspack.com www.schoellerarcasystems.us www.shuert.com www.gouldcincinnati.com www.pallets.com www.tedthorsen.com www.okpallets.com www.tdplastics.com www.universalpackage.com www.grainger.com
Litco LRM Industries International Inc. Mar-Pak Inc. MDC Packaging Inc. Millwood Inc. Niagara Pallet & Recyclers Ltd.
Orbis Pasadena Skid & Pallet PDQ Plastics Inc. Polycel Structural Foam Polymer Solutions Intl. Port Erie Plastics Rand Material Handling Equipment Reusable Transport Packaging Schoeller Arca Systems Shuert Industries Inc. Stephen Gould of Ohio Stratis Plastic Pallets Ted Thorsen LLC
Thermodynamics Triple Diamond Plastics Universal Package Systems LLC W.W. Grainger Co. Inc.
Greenovations
air q u a lity | heat r ecover y
Mechano-electret filter media captures submicron-sized particles, reduces energy costs

Kimberly-Clark Professional Filtration Products offers a family of mechano-electret particulate filtration media for HVAC applications in industrial and commercial settings. The electret charge (via corona charging) allows the filter to capture smaller, submicron-sized particles. Filtration efficiencies from MERV 7 to MERV 15 are available. The filter medias low airflow resistanceboth initially and throughout the filters service lifemeans that the HVAC system motors need to overcome less resistance to deliver the required airflow to the system, which helps reduce HVAC system energy costs. With the media, sustainability and indoor air quality can be improved while overall operating costs are reduced, the company states.
Kimberly-Clark Professional 1400 Holcomb Bridge Road, Roswell, GA 30076, 800-241-3146, www.kcfiltration.com
ERV products dehumidify makeup air

Munters offers the DryCool line of energy recovery ventilation (ERV) products, designed to meet dehumidification requirements for entire buildings and provide 100 percent makeup air at space-neutral temperature and below space humidity. The core of the technology is the condenser-reactivated desiccant wheel. The evaporator coil provides cooling before the desiccant process, and energy-recovery devices such as heat recovery wheels and heat pipes can be incorporated to help optimize performance. The product line saves up to 40 percent of energy costs associated with treating ventilation air and helps buildings earn LEED credits, reports the manufacturer. The units, available from 200 to 16,000 CFM, are applicable to all buildings.
Munters Corp. 356 Simmons Drive, #103, Cloverdale, VA 24077, 800-843-5360, dhinfo@munters.com, www.munters.us
46
Product News
Road sign recycling
Northwest Sign Recycling performs recycling of outdated, weathered aluminum signs, transforming them into clean, reusable blanks. The company hydrostrips about 15 tons of road signs per year. After stripping the old laminates, the company refaces the signs and puts them back into service. The company also recycles an additional 30 tons of signs per year, a process that uses less energy and creates a lower environmental impact than producing new aluminum. Aluminum does not exist in its pure form in nature; it must be extracted from ore and produced. Aluminum production is a relatively energy-intensive process that requires some 13 million watt-hours per ton of metal produced. On average, it takes 15.7 kWh of electricity to produce 1 kg of aluminum. Recycled aluminum, however, requires only 5 percent of the energy used to make new aluminum because of its lower melting point.
Northwest Sign Recycling, 877-234-1893, www.nwsignrecycling.com
36,000-lumen high-bay lighting fixture

LightWild has announced the availability of the Essentials Bay Series v 2.0 high-bay lighting fixture in its Lusio Commercial and Industrial brand of lighting products. The six models in the series have been redesigned into lighter fixtures that deliver up to 36,000 lumens and efficacies up to 111 lumens/watt at mounting heights as high as 50 ft. With options for integrated occupancy sensors, they are fully controllable for incremental energy savings. Each fixture is available with an integrated emergency battery pack and numerous optical, mounting, and cord/ plug options. All models have been UL listed in the U.S. and Canada and CB certified for global compliance.
Lusio Commercial and Industrial Lighting, 913-851-3000, www.lusiolighting.com
Spray nozzles
Exair Corp. has introduced new external-mix spray nozzles that atomize fluids in round and flat spray patterns. The nozzles can be used when a high volume of liquid is needed and with liquids with a viscosity up to 800 cP. They combine liquid and compressed air to create a liquid coating that can be adjusted to meet application needs. They can coat, cool, treat, and paint a variety of products. Because they are external-mix, airflow and liquid flow can be controlled independently, which provides a precise liquid flow. The stainless steel construction of these atomizing nozzles adds to their durability and corrosion resistance.
Exair Corp., 800-903-9247, www.exair.com
Recycled facial tissue

Cascades Tissue Group has introduced the Moka line of unbleached facial tissue. The beige-colored facial tissue is made of a pulp mix composed of 100 percent recycled fiber, 80 percent of which is postconsumer material and 20 percent is recovered corrugated boxes. Its production is offset with 100 percent Green-e certified renewable wind electricity and releases a minimum of 30 percent less greenhouse gas (CO2) than what is used in traditional white recycled tissues, says the company. The line also holds certification with EcoLogo, Green Seal, and the Chlorine Free Products Association.
Cascades Tissue Group, 800-246-0711, www.afh.cascades.com
EPA Tier 4-compliant welding machines

The new, highefficiency Classic 300 HE and SAE300 HE diesel engine-driven welding machines from Lincoln Electric are suitable for pipeline, construction, and maintenance welding applications. The pure DC generator provides arc
control for SMAW, GTAW, GMAW, FCAW, and gouging processes in code applications. Both deliver 3,000 W of AC power from a 120- or 240-V duplex receptacle for power tools and lights. Compliant with the EPA Tier 4 engine emissions standard, both fuel-efficient units feature three-cylinder, watercooled, 1,800-RPM engines. The Classic 300 HE offers the Kubota D1503 engine, while the SAE-300 HE offers a
choice between the Kubota D1503 and the Perkins 403F-15T. The Kubota engine delivers 15 percent fuel savings at 300 amps at low idle versus the previous Classic 300 D model. The Perkins engine delivers 13 percent savings at 300 amps and 20 percent at low idle versus the previous SAE-300 model.
The Lincoln Electric Co., 888-355-3213, www.lincolnelectric.com
Product News
Filtered-separation vacuum
Ruwac has introduced the Extract Vac point-of-source extraction vacuum. The portable system offers continuous-duty operation and filtered separation for collecting fine dust particles into a solid all-metal container. With extended filter options such as HEPA, the vacuum provides a sanitary method for collecting dust for reuse without concerns of cross-contamination. It uses VPK series vacuum producers with airflow rates up to 216 CFM. Each vacuum is equipped with a totally enclosed, fan-cooled, continuous-duty motor and mounted on a stand for stability.
Ruwac, 413-532-4030, www.ruwac.com
Air handler units with energy-saving options

Daikin McQuay offers a custom air handler line that provides unlimited configurations. The customizable units can attain a maximum of Class 6 leakage. Engineers can vary the length, width, and height in 2-in. increments so that the units can fit into critical spaces and through fixed doorways. Options to add access and service vestibules and to choose door handle and swing types facilitate accessing and servicing the unit in small or restricted access areas. A lowleakage cabinet construction incorporates a patented splice collar design, and welded frame channels eliminate the need for field-installation caulking.
Daikin McQuay, 800-432-1342, www.daikinmcquay.co
Zero-discharge-capable washbay station

Riveer has introduced the Washmaster 500, a portable, low-profile wash rack system that washes industrial and commercial equipment. The system removes oil, emulsions, grease, and other grime and cleans, contains, and filters washwater, removing contaminants for recycling or proper discharge to a drain. The washwater treatment unit can function as a zero-discharge system for closed-loop recycling processes. The systems RTS 500 washwater treatment system includes a large-capacity, small-footprint recycle unit featuring an inlet screen basket to capture contaminants before the filtration chamber. It includes oil coalescing and disk oil skimmer, ozone injection, 24/7 recirculation, back-washable media filtration, and absolute filration to keep degreasing solution clean.
Riveer, 269-637-1997, www.riveer.com
Portable power station

Van Straten Brothers Inc. has introduced the third generation of its X3 portable power station. Capable of providing both solar and wind power on battery reserves, the system opens up from a conventional ISO shipping container. The unit, which includes a diesel generator backup, features a 60-amp, 240-V, 14.4-kW inverter. Features include self-deploying hydraulic outriggers, a hydraulically deployed turbine boom, a quick-change pallet system for the batteries and generator, and a Smart Control designed to start the diesel generator automatically for continuous power.
Van Straten Brothers Inc., 906-523-7131, www.x3energy.net
ER-style ball bearings

Baldor Electric Co. has introduced a new line of BaldorDodge ER-style ball bearings, available in two shaft attachment methods. The set-screw version has a 65-degree set-screw angle to increase shaft grip. It is available in bore sizes from 0.75 (204 series) to 3.4375 in. (218 series). The D-Lok product offers a clamp collar grip for concentricity to minimize vibration. It is offered in bore sizes from 0.75 (204 series) to 2.4375 in. (212 series). The products employ snap-ring retention to fit the cylindrical OD into user equipment. The bearings also feature the Dodge ProGuard seal and flinger package to prevent contamination and maximize product life in dirty applications.
Baldor Electric Co., 479-646-4711, www.baldor.com
Dust collector
RoboVent has introduced the new Fusion 3 series of fume and dust collectors. The all-in-one collector is completely assembled and doesnt require any additional parts or equipment to be operational. With two connectionselectrical and compressed airthe collector is designed for welding, cutting, and metalworking operations. The Dynamic Pulse cleaning system comprises integrated valves with a computer-synchronized, double-pulse action. Milliseconds after a filter is purged, the surrounding filters are given a secondary purge to neutralize the airflow and propel the dust particulate into the collection area. This prevents the dust from being redeposited on the filters.
RoboVent, 888-762-6836, www.robovent.com
48
Product News
Zero-emissions, electric-powered lift truck
Yale Materials Handling Corp. has launched the new Yale ERP080-100VM zero-emissions, electric-powered lift truck series. The sit-down, pneumatic-tire lift truck series is available in 8,000-, 9,000-, and 10,000-lb. models. The series comes with a standard 80-V control system and extended shift feature. The new platform uses AC transistor control technology that allows load handling with less noise, while the AC motors eliminate brushes. The series uses auto deceleration, which slows the truck automatically through regenerative braking. The trucks oilcooled wet disc brakes are sealed completely from water and other contaminants. When maintenance is required, removable floor and side plates provide access to serviceable components. Featuring a drop battery box design, the series provides a low seat position and low step height.
Yale Materials Handling Corp., 800-233-9253, www.yale.com
Emissions-reducing scrubber
Alcoa has introduced the In-Duct Scrubber, which reduces emissions at industrial facilities. The technology is under construction as part of a commercial-scale demonstration project at the companys baked anode and calcined coke facility in Lake Charles, La. According to the company, the scrubber will remove as much as 90 percent of sulfur dioxide, particulate matter, and hydrogen fluoride emissions at the plant. Commissioning and on-site testing of the project is expected to be complete in August 2014. The company says that compared to traditional wet scrubbers developed originally to reduce emissions at power plants and large industrial facilities, the new technology can reduce scrubber installation and operating costs by approximately one-third for aluminum smelters and refineries, mostly as a result of improved processes and increased energy efficiencies. It uses 50 percent less water, consumes 30 percent less energy, and is more compact, adds the company. The new scrubber is designed to reduce sulfur dioxide and particulate matter emissions generated from aluminum smelters as well as small to intermediate industrial boilers from 50 to 120 MW.
Alcoa, 412-553-4545, www.alcoa.com
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Solatube International . . . . . . . . . . 17
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Under Cover
Bridge made of recycled plastics to span 50 years
Onion Ditch Bridge supports zero-waste goal

eaching over Onion Ditch in Logan County, Ohio, is the appropriately and simply named Onion Ditch Bridge. Although it is not remarkably named or remarkably long, it is remarkable in its composition: The materials used to make the Axion STRUXURE infrastructure building products are 100 percent recycled, including postconsumer plastic detergent bottles, shampoo bottles, and milk jugs, and postindustrial car bumpers and dashboards. Logan County Engineer Scott Coleman stated that durability and an expected life span of over 50 years weighed into the decision to use the recycled structural composite as well
50
as the environmental benefits of using recycled materials. The startling realization that petroleum-based plastic food containers have life spans of up to hundreds of years in landfills has prompted many to recycle plastic. The Logan County community has set a goal to be a zerowaste county by 2020. Advancements in technology are creating new economics and feasibility around recycled building materials, said Axion President and CEO Steve Silverman. STRUXURE bridges are engineered from Axions patented recycled plastic formulation using 100 percent recycled consumer and industrial plastics. Be-
cause the recycled structural composite material is inert, bridges made with it will not rot or absorb moisture, and they are impervious to insect infestation. The structural building materials are used to construct short-span vehicular bridges, multispan superstructures, and boardwalks. The 24.6-foot-long Onion Ditch Bridge is only the second bridge of its kind on a public road; the other is in York, Maine. The bridge was completed May 29.
Axion International Inc., 180 South St., Suite 104, New Providence, NJ 07974, 908542-0888, info@axih.com, www.axionintl. com/products-composite-bridges.html
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Giants footprint shrinks in the wash

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Some Of Our Customers Can Live With Leaky Roofs.

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September/October 2013 Vol. 4 No. 5

Your guide to adopting green manufacturing practices

White Castle manufacturer lights up at plants lighting, 28 controls retrofit

34 Texas plants fans cool workers, reduce drying time

38 Control scale to optimize HVAC equipment energy efficiency

green MANUFACTURER September/October 2013

Surveying the Greenscape

Re: Readers respond to Efficiency is power. Ecosavvy Newsmakers

Green Manufacturer Network Connections Reusable Pallet Directory

46 Greenovations Mechano-electret filter media captures submicron-sized particles, reduces

Product News Advertisers Index Under Cover

Printed on recycled paper, 30% postconsumer

Surveying the Greenscape

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Green at Every Turn

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Remove existing lens or louver

Remove existing lamps and ballast cover then disconnect power

Insert completely assembled LDR into existing bracket holes

Reconnect wiring to LDR

Close the LDR and latch

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green MANUFACTURER September/October 2013

Aveda launches packaging collection, recycling program

Randall Mfg. recognized as a 2013 Top Green Provider

Where Safety Meets Where

green MANUFACTURER 11 September/October 2013

Sustainable Biodiesel Certification program launches

Carbios collaboration supports creation of biotechnology laboratory for bioplastics

Coca-Cola, WWF partner to advance sustainability stewardship

Grainger opens LEED-certified, platinum-rated distribution center in Illinois

ABB director receives award from Green Parking Council

Solatube Intl. launches rebranded website

Smith Electric eet surpasses 700 vehicles, 5 million miles of operation

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