November-December 2008

Synergy

Water and light collide under Lightolier’s environmental stewardship.

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A criticism often heard about those who are making great efforts to improve and preserve our environment is that we tend to emphasize just one aspect of the environment: water, air, wastewater, solid waste, or energy efficiency. The criticism may be valid, so I looked for a non-public place where there are great efforts being made in several aspects to improve our environment. The word synergy, or synergism, comes to mind. It describes a condition where the combined effect of different components adds up to more than the sum of the individual effects. I came across the Philips Group—sometimes known as Royal Philips, with success in the fields of healthcare, lighting, and consumer products—that has an international reputation for environmental friendliness to accompany its unparalleled success in commercial ventures. In the United States, one of the Philips Group brands is Lightolier.

“Lightolier has worked on the conservation of water, electricity, and other resources and materials used in our manufacturing process aggressively during recent years,” observes Ron Westgate, Facilities Engineer for the company. Lightolier is headquartered in Fall River, MA and provides a wide range of lighting products for commercial, institutional, and residential lighting needs.

Founded in the early days of electrical lighting, the company pioneered significant innovations in the field, including track lighting, recessed downlighting, and high-performance, energy-efficient fluorescent. “Many projects have been successfully implemented in these areas of conservation and they have greatly reduced our use of power,” says Westgate. “Over the last year, we have zeroed in on water conservation with the same focus.”

Successful programs don’t just happen, and, as implied in the opening paragraph, the best environmental plans (public or private) take into account as many components as possible, to have them work together, to create a synergy that benefits as many as possible with their combined power. “In order to achieve the greatest success, a plan has been followed in this process,” says Westgate, about Lightolier’s efforts. “It was imperative to identify a mission statement for the plan, identifying the company’s position on Resource Conservation as it applies to our manufacturing process and overall sustainability goals that incorporate Lightolier and Philips objectives.”

The statement developed for the water conservation plan is this: In terms of the environment, sustainability is often defined as “meeting the needs of the current generation without compromising the ability of future generations to meet their needs.”

“We do not view this as simply being a good corporate citizen,” says Westgate. “Rather, we believe that sustainability is a sound business practice, and, when effectively integrated into our fundamental strategies, it delivers a solid bottom line. In practice, Lightolier, a Philips Group Brand, addresses sustainability both in our products, and in the way we make them.”

Lightolier is committed to producing and providing sustainable lighting systems, lighting that meets users’ needs with the least consumption of energy and other resources.

Water Use in Manufacturing
Lightolier began by identifying the usage and purpose of water throughout the facility. A detailed process flow diagram was developed as a working aid to the process. This defined that, in fabrication, the hydroforms, hydraulic presses, and hydraulic spinning machines use non-contact cooling water as a coolant for the hydraulic oil in the machine reservoir by flowing the water through a heat exchanger; it is then piped and reused in process rinses. That accounts for 40% of the facilities’ water usage total. In the finishing departments, the anodizing, powder coat, and aqueous wash lines utilize water for both rinsing and scrubber operations. This accounts for a further 55% of the facilities’ water usage total. The remaining estimated 5% is used for sanitary and maintenance.

“Our next step was to identify options for reductions,” comments Westgate. “Options were identified by evaluating the overall industrial wastewater flow, discussions with plant personnel who operate the various equipment using water, a walkthrough with our plumbing contractor, discussing use and alternatives to current use or procedures, and outside vendors who could help identify options. The key to this step, in each case, was to keep asking why we use water and do we need it? If it is needed, then can it be reduced and how?”

The major options identified were:

• Reduction of plant water pressure
• Reduction of rinse rates at anodizing, powder coating, and aqueous wash
• Enhanced reuse of non-contact cooling water
• Reduction of irrigation water used for the lawn
• Reduction of flush volume for toilets and urinals

“Options were screened for both technical and economic evaluation,” explains Westgate. “All options will be implemented, and we will consider any additional options which we may become aware of during implementation of improvements. The return on investment of the capital required is less than one year.”

Lightolier has set a 30% reduction in the use of water as its goal for the end of the year. “We are [as of July 2008] about 50% through the implementation, with the major equipment needed such as new pumps, variable frequency drives, and solenoid-operated isolation valves having been received this week,” says Westgate.

“We expect to complete the original options identified by mid-fall,” he adds. “The process will continue with the ‘fine tuning’ of our overall usage, because this type of process is really part of continuous improvement, and its success is dependent on the input and support from the hourly worker to the president of our company. With the full support we have on this from everybody, I expect that we will exceed
our goal.”

The State of Massachusetts has been helpful in this process. Under the Executive Office of Energy and Environmental Affairs (EOEEA), the Office of Technical Assistance (OTA) ran workshops in December 2007 and January 2008 on conservation training. Completion of training allows one to certify Resource Conservation Plans that are submitted to the Massachusetts Department of Environmental Protection as part of the Massachusetts Toxic Use Reduction Act amendments. The approach is unique for every company, because each is a little bit different, but Lightolier had a terrific benefit in this process.

“In the fall of 2007, the OTA asked if we would be the case study used for the training,” says Westgate. “Having worked with OTA closely on Toxic Use Reduction, we naturally were excited to work with them again and agreed. While developing the case study, which included electricity, natural gas, and water, we were able to lay a lot of the groundwork for our Water Conservation Plan.”

Addressing Production That Is Truly Green
To claim to be “green” has become a tactic for many companies, and the motivation comes from consumers who are increasingly conscientious about the environmental impact of the product choices they make, whether it’s a product as big as a car, or as small as a cosmetic item on a bathroom shelf. The guidelines set by governments at all levels—local, state, and federal—are more stringent than even a few years ago, and that may seem to make it especially difficult for long-established companies to comply. Lightolier, however, is an old company, active since 1904, and its example is surely one that could be followed by many others who may have claimed that “It just can’t be done,” or “We’ve never done it like that before.” As Westgate has pointed out, the changes at Lightolier are not mere lip service to customer demands; these are real, measurable, and beneficial changes.

Photo: Lightolier

Lightolier has taken a number of steps to cut volatile organic compound emissions dramatically at its Wilmington, MA plant.

Another word that comes in the vanguard for beneficial change, apart from synergy, is sustainability. It’s a word with many, slightly varying, definitions, but it always implies the long-term maintenance of new efforts or longevity. It has been used so often by different media that one cannot truly write a perfect definition. One interpretation of sustainability began with the 1987 publication of the United Nations World Commission on Environment and Development report, “Our Common Future.” Also known as the Brundtland Report, this document defined sustainable development as “development that meets the needs of the present without compromising the ability of future generations to meet their own needs.”

In many ways, it’s the opposite of the traditional quick fix.

“Sustainability is of paramount importance to Lightolier, and both our products and manufacturing policies reflect that,” advises Zia Eftekhar, president of Lightolier. “Every individual in our organization, from top management through manufacturing employees, is committed to make Lightolier a safer place to work and a more environmentally conscious member of the community.”

Closely related to good water in the minds of most consumers today is clean air. The two can go beautifully together like fresh air and water. Every community understands that the pollutants that go into the air from industry and agriculture, for example, don’t simply vanish skywards. They come down with the rain and enter our groundwater and watercourses.

Photo: Lightolier

"By having a green process from the ground up, we provide a safer workplace while manufacturing energy-efficient lighting fixtures in an environmentally-conscious manner," says Westgate.

For years, the emphasis was on vehicles and the inexorable polluting of air, and, then, water. In such emphasis, the dangers of industrial water use and air pollution were sometimes shielded from public reaction. I have met people who have complained about “the pollution from that factory” as if it were an alien attacker, without realizing that they, themselves, use the products from that factory every day. It’s not been a deliberate neglect, just a way of conducting business that is no longer prudent or acceptable.

“The very process of modern manufacturing poses a significant environmental challenge,” notes Westgate.

Traditionally, the manufacture of lighting materials involved the use of highly toxic chemicals and a great deal of water and oil consumption. Lightolier has taken a number of steps to cut volatile organic compound (VOC) emissions dramatically at its Wilmington, MA plant.

Westgate provided these details for our edification:

• Lightolier has reduced the use of vanishing oil by 16 tons per year—a reduction of more than 50%—by designing a refined applicator control on each press line that limits use.
• Lightolier has switched entirely from waterborne paint enamel (which contains isopropyl alcohol, a VOC) to powder coating, eliminating outdoor air emissions from the spray booths. The use of natural gas, no longer needed to heat the paint in the winter, has also been significantly diminished.
• Because of the use of powder coating, Lightolier now uses less airflow than required by the high-volume,  low-pressure guns and air turbine applicators that had been used to spray liquid paint. This greatly reduces the amount of paint used, saving money and lowering emissions.

The OTA supported Lightolier’s efforts with extensive training sessions and workshops that explored new, safer methods for cleaning, rinsing, chemically treating, and coating metal parts. In keeping with its corporate environmental objectives, Lightolier has been engaged in the Commonwealth’s pollution prevention assistance initiative since the late 1980s. The OTA recognized Lightolier in an official ceremony on August 15,  2007. The event included an acknowledgement of the company’s achievement from EOEEA Undersecretary for the Environment Phil Griffiths and a tour of Lightolier’s Tech Center and manufacturing floor.

All Photos: Lightolier

Water is piped and reused in process rinses.

Water use in the factory depends on the active cooperation of everybody in the company.

Reduction of plant water pressure has been a key step in progress.

“By having a green process from the ground up, we provide a safer workplace for our employees while manufacturing energy-efficient lighting fixtures in an environmentally conscious manner,” says Westgate. “But we’re not stopping here—we’re always exploring ways to cut emissions further and improve our practices.”

Power Changes Before, With Recycling After, the Manufacturing
Water… air…. waste… Whatever we make there will be waste, whether it’s sawdust from our home carpentry, metal shavings, and odd-shaped bits from steel fabrication or the liquid wastes formed by manufacturing processes with machines. In a perfect world, we’d be able to use every part of the cow, but the generation of energy and product inevitably results in leftover material. From both an environmental and a financial perspective, it is in the best interests of any manufacturer to make the best and most complete use of all materials used in production.

“Little things add up,” says Bob Wedekind, general manager of Engineering Services for Lightolier. “We don’t like to throw things away when there’s a clear use for them.”

Lightolier has found a practical number of interesting ways to do just that.

• Lightolier reuses water from the cooling process at its Fall River plant and the louver wash system at its Wilmington plant.
• In Wilmington, Lightolier installed flow meters and automatic clock shutoff on the water to the paint system rinse tanks, cutting its overall plant water/sewer fee in half.
• In both Wilmington and Fall River, the overspray from the powder painting is collected and reused automatically in a closed loop system.
• In Fall River, anodizing acid, once spent, is sold to a fertilizer company. This helps to minimize waste and make the most of available resources.

In addition, the company maintains an extensive recycling program that spans the corporate offices, as well as the manufacturing floor. Lightolier recycles all spent lamps and ballasts, corrugated paper and computer paper, aluminum, and steel scrap metal. Lightolier continues to replace older magnetic ballasted luminaries with electronic versions, and makes every effort to design its products in order to reduce the use of raw materials (and the water involved with those processes).

Here’s another component of the synergy that has powered the company to a leading position in manufacturing responsibility and competence. Minimizing the output of the manufacturing process is a significant achievement, but what about the energy flowing into it? Lightolier has demonstrated its concern about the energy used to power manufacturing and production, not only in one-time projects, but in the everyday operations of the company. “When not in use, shut it off.” The manufacturer widely recognized as providing the best in interior lighting requires its workers to shut those lights off whenever possible. This companywide effort is enforced with an extensive sign campaign, and hundreds of the lights are controlled with daylight and occupancy sensors. Since the start of the campaign, Lightolier has noticed a 9% reduction in energy.

“It’s amazing how the small energy saving efforts start to add up,” says Wedekind. “Everyone has been extremely cooperative—we’re lighting professionals, and we love good lighting, but we also know that there’s no need to expend energy where it isn’t needed.”

With oil at injurious prices and national concerns growing about our relying too heavily on foreign sources of energy, Lightolier has taken the first step toward generating its own power. In late 2006, the company received funding from the Massachusetts Technology Collaborative (MTC) Large Onsite Renewables Initiative (LORI) to conduct a wind feasibility study. MTC LORI grants are available to companies that are developing large-scale renewable energy generation systems, as well as feasibility studies for potential projects. Lightolier subsequently conducted extensive wind feasibility research to determine whether or not there was sufficient wind energy in the Fall River Industrial Park to power a turbine, which could provide a renewable source of energy to the company headquarters and manufacturing facility. The initial results of the research have been positive, and Lightolier has initiated the next steps toward approving and building a wind turbine. According to the MTC, about one-third of all energy consumed in the United States is used for heating, cooling, lighting, and appliances in commercial buildings. Harnessing wind power where available can significantly reduce the consumption of oil and other nonrenewable energy sources. “We are very excited to be recognized by the MTC and by the possibility of constructing an alterative power source for our manufacturing plant,” says Wedekind.

Lightolier’s sustainability efforts have attracted attention from several of the organizations that legislate and advise about sustainable practices. In addition to the OTA recognition from 2007, Lightolier is a member of the US Green Building Council, the nation’s leading nonprofit consisting of corporations, builders, universities, and government agencies working together to transform the built environment through green building practices. The Council developed the Leadership in Energy and Environmental Design (LEED) Green Building Rating System and hosts Greenbuild, the industry’s largest annual green building conference and expo. Lightolier also works closely with Energy Star, a government-backed program helping businesses and individuals protect the environment through superior energy efficiency. All products, homes, and buildings rated must meet stringent efficiency and environmental standards before receiving the Energy Star approval stamp.

“Our goal with Energy Smart Lighting is to empower our customers,” says Eftekhar. “We offer products that contribute to a sustainable world while meeting the needs of those who use them, and we demonstrate how to go about using lighting more efficiently. The power to change our environment for the better rests in all of our hands, and we can start by eliminating waste at all levels —from manufacture to installation, to our everyday use of light.”

Author's Bio: Contributing writer Paul Hull focuses on topics related to technology, finance, and safety in the excavation and construction industry.