Energy and Environment

•People•Planet•Profits

1. Our products-Consumer & Commercial2. Our corporate strategy3. Our local strategy

“A society grows great when old men plant trees whose shade they

know they shall never sit in.”(Greek Proverb)

Building supply dealers & big box stores

Advantage ICF System®Insulated Concrete Forms

EIFS-Exterior Insulated Finishing Systems

• Show insulspan job site sign

Insulspan-Structural Insulating Panels

CORPORATE SUSTAINABILITY

From a focus on promotionof benefits towards ….

Internal sustainability andexternal transparency

Sustainable Materials and Processes

Measurement and Reporting

Manufacturing Initiatives

Transparency

Become recognized for your actionsnot just your words.

Transition to Sustainability

Setting Targets for Improvement

Reduce energy consumptionReduce waste outputReduce emissions to the environment

Sustainability - Journey of Continuous Improvement

Continuous improvement implies a process without end

Similar to other continuous improvement processes– Lean Manufacturing– ISO– Six Sigma

Identify, measure, set targets, implement action, measure, analyze and set new targets/actions

PFB’s Sustainability CommitteeSustainability Committee

Chair

Economic Sub- Committee

Product Sub-Committee

Employees Sub- Committee

Environmental Sub-Committee

Product Responsibility

-Product use & end life issues

-Digital Information

-Packaging & labeling

Human Rights & Labour Practices

-Employee Involvement

-Social Responsibility

-Training

-Policy development

-community Outreach

Environmental Performance

-Lean Manufacturing

Resource Utilization

-Emissions

-Energy Utilization

Economic Performance

-Project Analysis & Justification

-Risk Analysis

-Annual Report

Scrap EPS Waste-one man’s trash is another man’s gold!

Scrap EPS Waste

Why is scrap EPS foam sent to landfill/recycling a problem?– Its worth something, EPS waste = $

• Energy to produce the material• Transportation to recycling• Manpower to move and load it• Space to store it

Poor image to portrayNot consistent with sustainability2012 Kitchener used 400,000 lbs of regrind

Plant Level Initiatives

Sustainable Lean Manufacturing

Energy & Environment

1.Electricity

2. Natural Gas

3. Water

4. Secondary Fuels

Waste Type Examples Environmental ImpactsDefects Scrap, rework, replacement production,

inspection-Raw material consumed in making defective products-Defective components require recycling or disposal-process energy-More space required for rework and repair, increasing energy used for heating, cooling and lighting

Waiting Stock-outs, lot processing delays, equipment downtime, capacity bottlenecks

-Potential material spoilage or component damage causing waste-Wasted energy from heating, cooling, and lighting during production downtime

Overproduction Manufacturing items for which there are no orders

-More raw material consumed in making unnecessary inventory-Extra products that may spoil (damage) or become obsolete requiring disposal-Extra hazardous materials used result in extra emissions, waste disposal, worker exposure

Motion/Transport Human motions that are unnecessary or straining, carrying WIP long distances, transportationExcess transport of WIP or products

-More energy use for transport-Emissions from transport-More space required for WIP movement, increasing lighting, heating and cooling demand and energy consumption-More packaging required to protect components during movement-Damage and spills during transport-Transportation of hazardous materials requires special packaging to prevent risks during accidents

Inventory Excess raw material, WIP, or finished goods -More packaging to store WIP-Waste from deterioration or damage to store WIP-More materials needed to replace damaged WIP-More energy used to heat, cool and light inventory space

Over processing More parts, more process steps, or time than necessary to meet customer needs

-More parts and raw material consumed per unit of production-Unnecessary processing increases waste, energy use and emissions

Unused Creativity Lost time, ideas, skills, improvements, and suggestions from employees

-Fewer suggestions for pollution prevention and waste minimization opportunities

Sustainable Lean Manufacturing-TPS

Source: EPA “Environmental Guide to Lean” August 2009 Report

• 2010 – Insulated facility– Installed contactors and light switches– OEE (overall equipment effectiveness “efficiencies”)-Lean manufacturing

• 2011 – New programmable high efficiency boiler– Replaced 30 x 400w metal halide with T8/T5

• 2012– Replaced 25 T12 lights with T8– Replaced 25 x 400w metal halide with T8 and motion sensors– Replaced 18 x 400w metal halide with T5– Changes to regrind system – used over 400,000 lbs. of material

• 2013– Replaced cutting system power supplies with high efficiency power supplies– Further changes to regrind system, to capture 95% of scrap material produced

Energy Saving Projects

Warehouse lights are off most of the time

Lights with sensors Turn off after 10 minutes

Recovered energy-diverting regrind from scrap…cost $3000, material/energy savings of $10,000/yr.

1. old system

2. old system

2.new system

1.new system

Lights w/sensor or illuminated switches for on/off use

Reverse Osmosis System

-Kitchener’s hard water drives up operational costs for process equipment such as boilers

-This has a negative effect on energy consumption due to constant “blow down”

-Equipment ROI is slow- Better option than increasing

CO2 - Better option then reducing

boiler life

The value of Continuous Improvement with sustainable manufacturing

1st reduction from lean activities

2nd reduction from electrical & boiler replacement

3rd reduction

from electrical changes & R/O system

• 2009 vs. 2012• -24 % electricity - $28,000 per year• -22 % H2O - $4,000 per year• -17 % NG - $30,000 per year

• CO2 reduction of 22 % per year• With a 20% increase in production!

– Without changes to energy usage we would have added $68,000 to our operating cost

• Total 2012 energy savings (including cost avoidance) ….$130,000

Reductions & Savings

Reduce, Substitute or Eliminate Methodology

While not directly specific to energy reductions, other little

things add up quickly!

Lift trucks- Pick the right equipment

Recycle oil-Compressor oil/water filter

System stores oil Filter sent out for recycling

• 2009: 102,750

• 2010: 94,454

• 2011: 85,017

• 2012: 83,063

• 2013: 79,800

• On track for a total reduction of 29%

Average Monthly Kwh consumption

• Energy– Lights – approx. 200 old T12 to replace– Motors – approx. 50 to be exchanged to energy efficient models– Compressor - VSD– Enernoc – DemandSMART response program

• Environment– Reusable/recyclable material programs-Waste EPS regrind– Launch oxo biodegradable wrap – Toxic Reduction Act

• Process Equipment– VOC reduction with new process equipment

Future Sustainability Projects

THANKS!

Questions?

• http://www.sustainableplant.com/– Great corporate tools

• http://www.emccanada.org/group_spaces/energy– Excellence in manufacturing

• http://cme.binaryoak.com/– Info about TRA Ontario

• http://www.greenpoweraction.com/business/BusinessCarbonOffsetCalculator.aspx– Calculate your carbon footprint

• https://saveonenergy.ca/Business.aspx– Financial programs

Resources