Cemex USA and Ford receive EPA Energy Star recognition

Initiatives aimed at energy management and greenhouse gas emissions reduction garner Cemex and Ford EPA 2010 Energy Star awards.

03/04/2010


The U.S. Environmental Protection Agency (EPA) has named Cemex USA a 2010 Energy Star Partner of the Year for outstanding energy management and reductions in greenhouse gas emissions. In related news, Ford Motor Companyearned its fifth straight Energy Star Award for Sustained Excellence.

Energy Star

Energy Star Logo. Source: Santa Clara University.

Cemex USA, an Energy Star partner since 2004, is receiving the Energy Star Partner of the Year award for strategic energy management and a commitment to save energy across its entire operation that has resulted in significant energy and financial savings. This isthe second year that Cemex USA has been named Partner of the Year. In 2009,Cemex reduced its overall energy intensity by 2.2% as a result of its energy management program using Energy Star guidelines. More than 1.1million MMBTUs were saved through such measures as commissioning two new cementlines using state-of-the-art vertical roller mills for finish grinding,replacing and repairing compressed air systems, and upgrading plant lighting.This energy savings resulted in cutting 107,500 metric tons of CO2 emissionsand is equal to providing electricity to 14,900 American homes for one year, oravoiding emissions from about 19,700 passenger vehicles.

The energymanagement program at Cemexemploys a corporate energy management team and a site energy teamat each plant to deliver on the company's energy conservation and sustainable manufacturing practices. Cemex cement plants in Clinchfield, GA,Davenport, CA, Knoxville, TN, Louisville, KY, and Wampum, PA, have all receivedEnergy Star certifications for their work to protect the environment throughenergy efficiency.

Ford's recognitionresults from the company's 2009 energy efficiency improvement of 4.6%,resulting in savings of approximately $15 million. Actions that have enabledFord's energy efficiency gains include updated heating and lighting systems andadvanced computer controls. The 2010 award marks the fifth consecutive year thatFord has been recognized with the EPA's Energy Star Award for its actions toreduce the amount of energy used to manufacture vehicles.

Since 2000, Ford's U.S. facilities have improvedenergy efficiency by more than 30%. That's equivalent to the annual energyconsumed by more than 110,000 homes. Actions taken by Ford since 2000 that havecontributed to its overall energy efficiency improvement include:

  • using flexible tooling to assemble multiple vehicles on the sameproduction line, which requires less manufacturing floor space andoptimizes plant utilization;
  • facility lighting system updates by replacing inefficienthigh-intensity discharge fixtures with up-to-date fluorescent lights andcontrol systems;
  • upgrading paint process systems, including booth air handling andimproved emission controls;
  • continued development of Ford's "Paint Shop of theFuture" processes, including fumes-to-fuel that turns paint fumesinto electricity, the 3-Wet painting process that significantly reducesthe footprint and energy use of paint booths, and zirconium oxidepretreatment that uses less energy to inhibit surface corrosion;
  • installation of advanced computer controls on all North Americanplant air compressors for paint shop applications and pneumatic tools;
  • use of a PC power management program to improve global energyefficiency with an estimated reduction in the company's carbon footprintof between 16,000 and 25,000 metric tons annually;
  • a "Go Green" dealership sustainability program to improvethe energy efficiency of Ford and Lincoln Mercury dealerships;
  • aggressively curtailing energy use during extended productionshutdown periods;
  • leveraging the Energy Star program through employee energyawareness communications and events, development of energy modeling andanalysis tools, and replication of industry best practices; and
  • updating heating systems at manufacturing facilities by replacingoutmoded steam powerhouses with digitally controlled direct-fired naturalgas air handler.


Access other Control Engineering contentrelated to energy efficient manufacturing initiatives:

 

 

-Edited by DavidGreenfield , editorial director
Control Engineering Sustainable Engineering
News Desk



No comments
The Top Plant program honors outstanding manufacturing facilities in North America. View the 2015 Top Plant.
The Product of the Year program recognizes products newly released in the manufacturing industries.
The Engineering Leaders Under 40 program identifies and gives recognition to young engineers who...
World-class manufacturing: A recipe for success: Finding the right mix for a salad dressing line; 2015 Salary Survey: Manufacturing slump dims enthusiasm
2015 Top Plant: Phoenix Contact, Middletown, Pa.; 2015 Best Practices: Automation, Electrical Safety, Electrical Systems, Pneumatics, Material Handling, Mechanical Systems
A cool solution: Collaboration, chemistry leads to foundry coat product development; See the 2015 Product of the Year Finalists
Digital oilfields: Integrated HMI/SCADA systems enable smarter data acquisition; Real-world impact of simulation; Electric actuator technology prospers in production fields
Special report: U.S. natural gas; LNG transport technologies evolve to meet market demand; Understanding new methane regulations; Predictive maintenance for gas pipeline compressors
Cyber security cost-efficient for industrial control systems; Extracting full value from operational data; Managing cyber security risks
Getting ready for industrial IoT; Visualizing the (applied) automation continuum; Preventing VFD faults and failures; Using wireless for closed-loop applications
Migrating industrial networks; Tracking HMI advances; Making the right automation changes
Understanding transfer switch operation; Coordinating protective devices; Analyzing NEC 2014 changes; Cooling data centers

Annual Salary Survey

After almost a decade of uncertainty, the confidence of plant floor managers is soaring. Even with a number of challenges and while implementing new technologies, there is a renewed sense of optimism among plant managers about their business and their future.

The respondents to the 2014 Plant Engineering Salary Survey come from throughout the U.S. and serve a variety of industries, but they are uniform in their optimism about manufacturing. This year’s survey found 79% consider manufacturing a secure career. That’s up from 75% in 2013 and significantly higher than the 63% figure when Plant Engineering first started asking that question a decade ago.

Read more: 2014 Salary Survey: Confidence rises amid the challenges

Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
The One Voice for Manufacturing blog reports on federal public policy issues impacting the manufacturing sector. One Voice is a joint effort by the National Tooling and Machining...
The Society for Maintenance and Reliability Professionals an organization devoted...
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
Maintenance is not optional in manufacturing. It’s a profit center, driving productivity and uptime while reducing overall repair costs.
The Lachance on CMMS blog is about current maintenance topics. Blogger Paul Lachance is president and chief technology officer for Smartware Group.
This article collection contains several articles on the vital role that compressed air plays in manufacturing plants.