LIGHTFAIR Afterglow–High-bay Shines

Monday, May 20th, 2013
By: Kate Bachman

The 2013 LIGHTFAIR® International expo, held in Philadelphia in April, was impressive, as always. I was especially pleased to see all of the high-bay lighting innovations suitable for industrial applications.
Although LED has definitely ARRIVED for high-bay applications, other lighting technologies shone brightly for high-bay industrial applications as well, including Solatube's tubular daylighting devices and American Green Technology's induction lighting.

Arrived: LED for high-bay applications.

- GE acquired Albeo for its high-bay LED lighting and showcased its Albeo™ ABHX-Series High Bay Fixture at the expo. "We recognized the need for energy-efficient lighting for manufacturing," said GE's Sean Veit.

Sean Vetz

Sean Veit, GE Lighting

The series' life, rated for 100,000 hours at L70, can replace a high-bay lighting systems from 250- to 1500-watt high-intensity discharge (HID) and four- to eight-lamp T5/T8 high-intensity fluorescent lighting. Veit, citing its longevity as a major asset, said, "Manufacturers can set it up and forget it for a decade."

- Cooper Lighting again exhibited its Metalux HB LED for industrial and other high-bay applications that use traditional HID and linear fluorescent high bays. It features precision-designed optics, available in multiple distributions, three lumen packages (9,000, 18,000 and 23,000) and two color temperatures (4000 K and 5000 K). The highly efficient HB LED offers 91+ lumens per watt.

- Juno and Osram/Sylvania exhibited high-bay LED offerings as well.

Larry Seurynck, AGT

Most Surprising Sleeper Technology: Induction lighting has been around for a long time, but American Green Technology led the charge at LIGHTFAIR to broaden its marketplace distribution and showcase its suitability for high-bay applications.

"Our induction lighting, with its broad footprint of light and full-color spectrum, is especially suitable for high-bay applications. It lasts 100,000 hours and can reduce electricity costs by 50 to 70 percent," Larry Seurynck, American Green Technology, said. The light is diffused, rather than point-sourced, he added.

Least Electricity-consuming: Solatube's Tubular Daylighting Devices. Once installed, the TDD harvests daylight, requiring no electricity input. Sunlight is captured by a dome and directed downward through a highly reflective tubing with engineered refractive capabilities. It redirects low-angle sunlight and emits consistent lighting throughout the day.

Gary Zullo, Arrow Electronics

The device can transfers sunlight more than 50 feet. Sunlight is distributed throughout the room. Optical lenses diffuse the daylight and block UV transmission (See the company's article, "New dawn of daylighting in industrial plants," in our May/June issue.)

The company introduced a smart version (Smart LED System) which integrates daylighting with LEDs.

Although an industrial version is not yet ready, one is in development and expected for release early next year.

Brightest not-a-lighting-company Booth:

Arrow Electronics. "We help lighting manufacturers transition to solid state lighting, said Gary Zullo, director of solid state lighting. The company provides access to the world's leading solid state lighting technologies with design and electronic engineering, production of the electronic guts of the solid state lighting system, and supply chain logistics.

"The solid-state technology has gotten to the point where you can actually buy fluorescent retrofit tubes that come with integrated power inside the tube to allow you to basically bypass the traditional ballast."

Vivek Muchalla, GE Consumer & Industrial Lighting

Best Control Improvement:

GE's new LightSweep™ Modular Lighting Control System provides a way for manufacturers to map a variety of system input devices such as switches, motion sensors and photocells—up to eight--to relays and smaller nested lighting groups.
It makes it easier to meet specification without having to over-engineer the control design and helps users implement advanced control strategies across lighting and HVAC systems. It can be integrated with any building automation systems and with most energy management software.

Most Prize-winning Lighting Material:

Dow Corning's new MS-1002 and MS-1002 moldable optical silicones for LEDs won an LFI Innovation award. The moldable aspect allows lighting designers to design with more complex shapes, thinner wall configurations, and once impossible designs for secondary optics, light pipes, and white reflecting parts. In addition, the manufacturer showcased advanced LED silicones that perform under high temperatures and harsh conditions. "These materials are driving new innovations in next-generation LED lighting designs, and expanding opportunities for solid-state lighting to compete with and displace traditional sources in more demanding high-intensity lighting applications," Hugo da Silva, global industry director of LED Lighting for Dow Corning, explained.

Hugo da Silva, Dow Corning

Coolest Lightshow: Cooper showboated its new scalable Wavestream(TM) in a rather dramatic lightshow in an auditorium section of its booth, demonstrating, with a series of lighting fixtures, how the technology can be used. The patented LED technology features laser-precise, AccuAir(TM) optics that are embedded and arranged in exacting patterns, the company says, offers superior optical control and takes LED mainstream.

Most Versatile: SWITCH Lighting launched what it claims is the first 3-way LED light bulb, the SWITCH 3-Way.

Most Dazzling: Philips' booth, although designed for manufacturers, was absolutely, hands-down, the most dazzling exhibit, showcasing its lighting in retail, patissieries, offices, and showrooms. The manufacturer also threw in a New Year's Eve drop ball just for the fun of it.

Most Suitable for High-bay Applications: All of the products showcased in our July/August issue "Lightfair Spotlight on High-bay" product showcase section. Look for the issue in late July.


Food waste and the Clean Plate Club

Thursday, May 16th, 2013
By: Kate Bachman

If you were a child growing up in America—especially a child of a child of the Great Depression, as am I—it's likely that you have been told to "clean your plate, because a child in (a developing nation) is starving."

I never could quite make the correlation between my eating all the food on my plate and feeding the hungry in distant lands, but I complied, and now I am wearing those food scraps on my hips.

Even today I cannot leave food on a plate, so I either adjust my portions or take home "doggie bags." Still not sure how that feeds hungry children thousands of miles away, but I certainly have internalized a value for things made and a distaste for waste. Read the rest of this entry »


Manufacturing energy use decline is an upper

Friday, April 5th, 2013
By: Kate Bachman

It’s good to get good news. And from a green manufacturing perspective, news doesn’t get much better than the recent news that the manufacturing sector’s energy use and energy intensity has gone down since 2002.

According to the U.S. Energy Information Administration, “Total energy consumption in the manufacturing sector decreased by 17 percent from 2002 to 2010.

Countering any misconceptions that the decrease is related to decreased manufacturing activity, manufacturing gross output decreased by only 3 percent over the same period, according to the EIA.

“Taken together, this data indicates a significant decline in the amount of energy used per unit of gross manufacturing output. The significant decline in energy intensity reflects both improvements in energy efficiency and changes in the manufacturing output mix. Consumption of every fuel used for manufacturing declined over this period,” the agency’s report stated.

The manufacturing sector comprised over 11 percent of gross domestic product (GDP) in 2010.

The ramification of this reduction is significant, in terms of accompanying emissions reductions, since energy concumption = CO2 emissions.

The reduction also helps void the need to build new coal-fired power plants.

Other benefits that may not necessarily benefit the environment certainly benefit manufacturers, in that lowered energy use equates to lowered overhead costs and improved competitiveness.

Who says no news is good news?


The emissions conundrum

Friday, March 22nd, 2013
By: Kate Bachman

I recently received a letter from a reader seeking a comprehensive list of all green manufacturing initiatives. Manufacturers I encounter at tradeshows and events often ask me, "Is there a definitive guidebook or a check list?" They say that they want to make sure that they're doing everything they can, and that what they're already doing really is green. One cannot be faulted for wanting a black-and-white, pure, This-is-everything-and-always-green testament.

Unfortunately, it's not that simple. Read the rest of this entry »


Super Bowl XLVII may be over, but blackout lives on

Monday, March 4th, 2013
By: Kate Bachman

NRG Energy, (NYSE: NRG), the Santa Clara Stadium Authority and the San Francisco 49ers announced an agreement to bring sustainable energy to the new Santa Clara Stadium. Through this unique partnership, NRG will help the new facility become the first professional football stadium to open with LEED certification, the recognized standard for measuring building sustainability.

As one of the first Founding Partners for the new stadium, and the exclusive sustainable energy provider of the 49ers, NRG will install a number of state-of-the-art solar elements, including three solar array-covered bridges, a solar canopy above the green roof on the suite tower portion of the stadium and solar panels over the 49ers training center.

The arrays will have a total peak capacity of about 400kW and will provide enough power over the course of a year to offset the power consumed at the stadium during 49ers home games. As a result the stadium will be the first professional sports venue in California to achieve net zero energy performance.

“NRG is much more than a Founding Partner, they are providing the energy leadership, infrastructure and expertise to help us achieve the vision of making the new Santa Clara Stadium an economically and environmentally sustainable showcase for innovation,” said Jed York, Chief Executive Officer, San Francisco 49ers. “As we strive to build a stadium that embodies all that is unique and special about both the Bay Area and Silicon Valley, this partnership with NRG will make very lofty goals become realities.”

The new stadium in Santa Clara is the next generation of stadium design.  One of the most unique features of the facility is the green roof atop the suite tower on the west side of the stadium. The three solar bridges, connecting the main parking area to the stadium, will include hundreds of solar panels.  In keeping with NRG’s philosophy of creating iconic solar elements at NFL stadiums, the solar bridges will be the first in the NFL.

"The 49ers are not only one of the leading and most successful franchises in the history of the NFL, they have also been for decades community leaders in the Bay Area and with the entire 49ers fan base. Today and going forward, we are honored to support the 49ers as they extend their off-the-field community leadership into the critically important arena of clean and sustainable energy," said David Crane, President and CEO of NRG Energy. “And NRG is proud to partner with the San Francisco 49ers and the Santa Clara Stadium Authority in the pursuit of another milestone, the LEED certification of their new stadium.”

In addition to the solar array, the stadium’s green initiatives include public transit access, convenient bicycle parking, a walking path from the San Tomas Creek Trail, water-conserving plumbing fixtures, recycled materials and a long list of other sustainable design elements.

As the sustainable energy partner of the 49ers, NRG will continue to explore other opportunities to help enhance the stadium’s sustainability efforts such as installing electrical vehicle charging stations to the new stadium.  NRG is currently building the nation’s first comprehensive, privately funded electric vehicle charging network.

NRG, the nation’s largest competitive power generator is a leader in providing safe and reliable energy solutions in new and innovative ways to American businesses and consumers.  It is also the largest solar power company in the United States with more than 900 megawatts of solar generation in operation.


Best of State of the Union Address

Thursday, February 14th, 2013
By: Kate Bachman

My favorite parts of President Obama’s Feb. 12 State of the Union address are the green parts. Not surprising. And the manufacturing parts. The flip side of the same coin, as I see it.

“Our first priority is making America a magnet for new jobs and manufacturing.

After shedding jobs for more than 10 years, our manufacturers have added about 500,000 jobs over the past three. Caterpillar is bringing jobs back from Japan. Ford is bringing jobs back from Mexico. After locating plants in other countries like China, Intel is opening its most advanced plant right here at home. And this year, Apple will start making Macs in America again.

I’m announcing the launch of three more of these manufacturing hubs, where businesses will partner with the Departments of Defense and Energy to turn regions left behind by globalization into global centers of high-tech jobs. And I ask this Congress to help create a network of 15 of these hubs and guarantee that the next revolution in manufacturing is Made in America.

“We are finally poised to control our own energy future …. We have doubled the distance our cars will go on a gallon of gas, and the amount of renewable energy we generate from sources like wind and solar – with tens of thousands of good, American jobs to show for it.

And over the last four years, our emissions of the dangerous carbon pollution that threatens our planet have actually fallen.

But for the sake of our children and our future, we must do more to combat climate change.
I will direct my Cabinet to come up with executive actions we can take, now and in the future, to reduce pollution, prepare our communities for the consequences of climate change, and speed the transition to more sustainable sources of energy.

Four years ago, other countries dominated the clean energy market and the jobs that came with it. We’ve begun to change that. Last year, wind energy added nearly half of all new power capacity in America. So let’s generate even more. Solar energy gets cheaper by the year – so let’s drive costs down even further. As long as countries like China keep going all-in on clean energy, so must we.

I propose we use some of our oil and gas revenues to fund an Energy Security Trust that will drive new research and technology to shift our cars and trucks off oil for good.

I’m also issuing a new goal for America: let’s cut in half the energy wasted by our homes and businesses over the next twenty years. The states with the best ideas to create jobs and lower energy bills by constructing more efficient buildings will receive federal support to help make it happen.”

I have no doubt that green manufacturers like my readers are playing an important role in making all of these aspirations become realities.


ProMat 2013 Is Pro-Green

Tuesday, January 22nd, 2013
By: Kate Bachman

This year’s ProMat expo at Chicago’s McCormick Place is a robust, boisterous, and well-attended event, propelled by an increasingly prosperous economy and a continent compelled to be in motion.

You don’t have to look hard to see that it is also steeped in green.

I focused most of my attention to lift trucks while performing research for my upcoming article to be published in the March/April issue of Green Manufacturer on trends in low- and no-emissions forklifts. Most of the major lift trucks manufacturers have eco-friendly product offerings, such as electric forklifts, low-emissions diesel-powered forklifts that meet the EPA’s Tier IV emission standards, and improved energy efficiency overall.

Raymond Corp.’s lift truck fleet is all-electric (zero emissions). The company has worked on improving the energy efficiency of the fleet, (under the Eco-Performance umbrella) including control (ACR) and motor improvements, and has had its fleet tested by independent, ird-party United States Auto Club (USAC) to prove it. Its Swing-Reach® truck was found to use up to 40 percent less energy.

The higher energy efficiency results in less battery charging, and reduced CO2 emissions.

Hyster Co. introduced its Certified Remanufactured Program, which enhances reuse of the lift trucks. In addition, the company showcased its new powerful indoor/outdoor electric forklift, engineered to withstand outdoor applications.

Enhancing the feasibility of electric lift trucks are several rapid-rechargers, including one from Minit Charger. The rapid rechargers negate the need for time-consuming and production-disruptive battery changeouts.

Although Toyota Material Handling is not exhibiting at the show, I had the opportunity to meet with company executives who relayed that the company has not only powered up its electric fleet to near-par capacities of internal combustion engine machines, it is close to releasing its Tier IV-compliant diesel truck, and offers several low-emissions ICE-trucks as well.

Toyota also manufactures liquid natural gas (LNG)-powered lift trucks and is the only manufacturer to offer factory-installed compressed natural gas (CNG) forklifts.

You still have time to attend the show, which ends on Thursday, Jan. 24.


Closing the loop, creating demand for green

Monday, January 21st, 2013
By: Kate Bachman

I had the opportunity to hear William McDonough speak at Greenbuild in November. McDonough is credited with co-creating the cradle-to-cradle concept. Meeting him in person was a $1,000-a-plate proposition, however. Suffice it to say that I did not meet Mr. McDonough.

Essential to cradle-to-cradle implementation is the creation of demand for the "second cradle" so to speak—the repurposed product.

Finding ways to create that demand requires some in-depth examination of the material composition of products and manufacturers' willingness to flex a little when selecting raw materials. And it requires imagination. Read the rest of this entry »


Green,hot and delicious

Wednesday, November 28th, 2012
By: Kate Bachman

For a crunchy-snack lover like me, cupping a handful of warm, fresh-from-the-oven, whimsically misshapen, and cheesy Cheetos® only inches from my tongue, saliva at the ready, was a dizzying experience.

The crunchy morsels never had a chance to see the inside of a film bag or be set on a grocery store shelf. Eating them was a primal response. Truly, you can’t eat just one.

And, oh yes, they were delicious.

I had the opportunity to sample the snacks while researching this issue’s cover story, which showcases the Beloit, Wis., Frito-Lay plant, where the region’s Lay’s® potato chips, Fritos® corn chips, Tostitos® chips, and Cheetos are made. (see "Snack-maker keeps plant toasty using heat recovery," p. 18) Read the rest of this entry »


Did you miss Greenbuild? Listen to the voices in my head

Monday, November 19th, 2012
By: Kate Bachman

Last week’s U.S. Green Building Council's (USGBC) Greenbuild International Conference & Expo, 2012, the world's largest conference dedicated to green building is over, but its voices still linger in my head.

Newark, N.J.  Mayor Corey Booker, on the controversial stimulus’ green investments: “I know that it is very controversial to spend our stimulus dollars on energy, but it is a good investment. We in America, unfortunately, spend so much money on the back end of problems …  it is so much more expensive, as opposed to making critical green investments on the front end that bring a healthier, more productive society.”

George Pataki, former Governor of New York, on how to advance clean energy: "The problem isn’t that government shouldn’t be trying to advance the ball and encourage a result; it’s that government shouldn’t be picking a company or a technology."

Read the rest of this entry »