DEEP: 2012 Business/Industry GreenCircle Award Recipients

GreenCircle Award Recipients
2012 Business / Industry Related

Name of Business/industry

Category/Activity

Description Of Activity

Aptar - Stratford
Stratford, CT

Execute changes that reduce annual energy or water consumption rates by more than 15% and implement a project to reduce greenhouse gas emissions consistent with Connecticut's Climate Change Initiatives.

Aptar - Stratford has reduced its electricity consumption thereby offsetting 442.5 metric tons of CO2. This is due to the following continuing efforts to reduce compressed air usage:

A premium energy efficient cycling generated dryer was installed on the compressed air system. This will result in an average annual savings of 143 metric tons of CO2, as calculated by United Illuminating.
 
Aptar has a policy to survey for compressed air leakage at least annually. In 2012, the finding and repairing of leaks resulted in a savings of 45.5 tons of CO2.

Aptar has approximately 84 assembly machines that require compressed air. It was recognized that compressed air runs continuously, even at times when the machine was in stand-by, no operations were taking place. A submeter was installed on a typical machine to determine a base case for electric and compressed air use. A solenoid was installed on the machine which would shut the machine down after three minutes of stand-by. Electric and compressed air readings were again tracked. The installation of a solenoid decreased the consumption of electricity by 15% and compressed air by 29%. It is Aptar's goal to have a solenoid installed on every machine. To date we are 50% complete. This equates to an avoidance of 254 tons of CO2.

Aptar - Torrington
Torrington, CT

Execute changes that reduce annual energy or water consumption rates by more than 15% and implement a project to reduce greenhouse gas emissions consistent with Connecticut's Climate Change Initiatives.

Aptar - Torrington reduced its electricity consumption thereby offsetting 615.8 metric tons of CO2. This is due to continuing efforts to replace inefficient equipment with high efficiency equipment, and performing an annual compressed air leakage survey.

In 2012 two hydraulic molding machines were replaced with electric molding machines. This equates to a savings of 243 metric tons of CO2.

Six micro molding machines were purchased which resulted in a savings of 122 metric ton equivalents of CO2.
A vacuum system that delivers resin from silos to molding machines was replaced.

The old system consisted of 7 10-hp motors and filters. This was replaced with 1 40-hp motor and cyclone filter, resulting in annual savings of 75.8 metric ton equivalents of CO2.

Aptar has a policy to survey for compressed air leakage at least annually. This resulted in a savings of 175 metric tons of CO2.

Bristol-Myers Squibb Co.
Wallingford, CT

Execute changes that reduce annual energy or water consumption rates by more than 15%; successfully implement an innovative and unique pollution prevention plan or recycling program that generates an environmental benefit; promote conservation and preservation of critical plant or animal habitats; implement habitat enhancements for fish or wildlife on public or private property; voluntarily contribute significant time or resources to environmental instructional programs; and donate significant time or resources to assist with environmental projects.

Over the years, Bristol-Myers Squibb Co. (BMs) has established various projects and associated sub-projects at its Wallingford campus. The implemented projects encompass three different categorical activities: 1) natural resources and environmental awareness including a pond restoration and Elodea removal project; 2) recycling efforts, and 3) energy conservation.

In the natural resources and environmental awareness category, the BMS wildlife team identifies opportunities for on-site habitat enrichment and species diversity such as developing the expansion of 2 on-site nature trails; developing of a pond management program to protect aquatic ecosystem which includes the establishment of no mow zones and reduced fertilizer use; increasing habitat for pollinating species by planting 3 flowering gardens, adopting a small woodland management plan to assure maximum habitat value; increasing employee awareness of wildlife habitat preservation; increasing natural buffers to wetland and riparian zones; increasing nesting habitat for avian species and establish a monitoring and nesting program for Bluebirds and Tree Swallows; adopting and propagating Connecticut's endangered species such as Stiff Goldenrod (Solidago rigida); and adopting a small woodland management plan to assure maximum habitat value.

Over the past 5 years, BMS has developed a waste minimization and recycling program that encourages recycling efforts both for employees and contractors working on site. The majority of recycled products are paper, plastics, cardboard, and non-burnables. To promote recycling efforts within the company, BSM distributes literature, coordinates special awareness events such as Earth Day and emphasizes the importance and responsibility of recycling during training and safety orientations.

The company's waste minimization and recycling team meets twice a year to review current recycling efforts, identify areas of deficiency, and discuss opportunities to improve the program.

BMS is actively involved in several green initiatives including water conservation and energy management. Some of the initiatives implemented include installing solar and LED lighting in a parking lot; adding controls to chiller to optimize equipment operations; upgrading mechanical equipment (chillers, pumps, air handlers) to high efficiency modifying levels, thereby minimizing energy consumption; installing low occupancy sensors; replacing windows to ensure proper gas seal/reflective material (229 windows); using energy efficient vending machines; reducing office lighting (reduce 70% light fixtures on 2nd floor); and conducting at least 2 energy audits per year (1-2% to offset energy costs).

Bull Metal Products, Inc.
Middletown, CT

Execute changes that reduce annual energy or water consumption rates by more than 15%; implement manufacturing processes that eliminate or significantly reduce the quantity or toxicity of a facility's waste stream; and successfully implement an innovative and unique pollution prevention plan or recycling program that generates an environmental benefit.

Bull Metal Products, Inc., utilizes a HSM Profi Pack Machine to reuse corrugated as packing material for shipping their products thereby reducing cardboard waste by 12%. A Jenfab part washer was purchased which is more efficient and reduced water consumption by 9%. Natural gas space heaters in the facility have been outfitted with Honeywell timer/temperature controls to automatically shut off during off hours. This has reduced natural gas costs by 10%.

Bull Metal Products has a partnership success with Leanovations and Traver IDC to pursue "Lean to Green" initiatives. They have conducted 6 Kaizen events, 3 internal and 3 Leanovations. They have initiated their ISO 9001:2008 certification process. Once completed, the goal is to continue to work towards ISO 14001 certification.

Chapman Manufacturing
Durham, CT

Successfully implement an innovative and unique pollution prevention plan or recycling program that generates an environmental benefit.

Starting in late 2010 and going forward, Chapman Manufacturing investigated what it would take to be recognized as a GreenCircle Award recipient. After reviewing the requirements, they implemented a new recycling program. Over the prior years their waste/garbage was all placed into one trash bin. Since then, they began using shredded office papers and forms as packing materials and started separating other cardboard and paper materials for recycling. They have a machine oil separator on location that they use to remove fine metal particles from their used machine oils, which enables them to continue to reuse the oil on a daily basis. They recycle scrap metal and old metal machinery with the Albert Brothers, Inc. out of Waterbury. All of their fluorescent light bulbs, batteries, and computer/electronics are brought to recycling days through the community, as well as, donated unneeded items (office equipment, chairs, books, etc.) to the Goodwill. Going forward in 2012, Chapman Manufacturing continues to implement new ideas such as adding two more recycling bins in its shop/office. One for returnable cans and bottles to be donated to the Boy Scouts at the local refuse facility, and the other for all other recyclable materials which will be brought to the local refuse facility for recycling as well. trash. While doing this project, they have noticed many employees are also doing this at home with their own trash.

Coilplus Connecticut
Waterbury, CT

Certify to ISO 14001; document and implement a facility-wide pollution prevention plan; and successfully implement an innovative and unique pollution prevention plan or recycling program that generates an environmental benefit.

Coilplus Connecticut is a steel service center. Last year, Coilplus implemented ISO 14001:2004, a single stream recycling program as well as recycling of ink cartridges, CFL bulbs, batteries, and paper shredding programs. Additionally, in September 2012 in conjunction with CRRA, the company hosted an onsite electronics recycling event.

Eagle Valley Eco Fuel, Inc.
Ellington, CT

Execute changes that reduce annual energy or water consumption rates by more than 15% and successfully implement an innovative and unique pollution prevention plan or recycling program that generates an environmental benefit.

Eagle Valley Eco Fuel, Inc., converts manure and stall waste into a biomass heat source. Patents are held on the process, both in the U.S. and abroad. This is an ongoing manufacturing operation that recycles solid waste on a daily basis and provides a clean, renewable energy source as a final product. The farms with greenhouses, in using their product to heat them, will at a minimum cut their energy consumption in half.

As result of recently enacted state and federal statutes and in an effort to clean both the soil and ground water quality, Nutrient Management has created a mandated need to find sustainable process to remove manure from the ecosystem. Eagle Valley’s process and products are renewable, economical, reduce carbon emissions and lower green house gases.

In producing a renewable fuel source, farms can become a solution to their natural resources dilemma.

Environmental Office Solutions
East Hartford, CT

Certify to ISO 14001 and successfully implement an innovative and unique pollution prevention plan or recycling program that generates an environmental benefit.

Environmental Office Solutions, Inc., is in business to help companies, government agencies and consumers recycle their used toner and inkjet cartridges from printers, copiers, facsimile and MFPs (multifunction printers), as well as used cell phones.

As of June 19, 2012, Environmental Office Solutions, Inc., has been certified to R2:2008 (Responsible Recycling Practices), ISO 14001:2004, OHSAS 18001:2007 and is also ISO 9001 compliant.

Within their warehouse and processing facility they work with several vendors for product waste. As an example, all cardboard, stretch film and soft plastic packaging is baled and sent for recycling. During the first five months of 2012 close to 170,000 lbs of these materials have been recycled.

GreenShare Technology
Farmington, CT

Successfully implement an innovative and unique pollution prevention plan or recycling program that generates an environmental benefit and voluntarily contribute significant time or resources to environmental instructional programs.

GreenShare Technology is a non-profit organization with the mission of providing low cost computers and training to those who cannot afford new technology. As part of their mission they take unwanted computers from businesses, organizations and individuals to repurpose them for schools and libraries, and for students, individuals and people with disabilities for home use.

They team up with Connecticut schools to offer electronics recycling events. In 2012 they held two public events to collect, repurpose and recycle more than 8,000 pounds of electronic waste while also ensuring safe data destruction and provided more than 25 usable computers back to the local communities. Through August 2012, GreenShare has repurposed and distributed more than 110 free or low cost computers in the state while keeping usable computers from local landfills. To date, their volunteers have contributed more than 1,500 hours to saving unwanted computers.

G-Zen, LLC
Branford, CT

Execute changes that reduce annual energy or water consumption rates by more than 15%; implement clean energy generation projects utilizing fuel cells, solar, geothermal or wind power; implement a project to reduce greenhouse gas emissions consistent with Connecticut's Climate Change Initiatives; convert or purchase fleet vehicles that run on natural gas, electricity, hybrid gas/electricity, or other alternative fuels or vehicles having a mileage rating of greater than 40 miles per gallon and an emission standard level of ultra low or cleaner; voluntarily contribute significant time or resources to environmental instructional programs; and donate significant time or resources to assist with environmental projects.

Gzen is a fully sustainable restaurant and is considered a ZERO waste establishment. Gzen uses 90% organic ingredients, 100% vegan ingredients which are sourced locally within 25 miles from the restaurant. Many of the ingredients for GZEN are grown on the owner's organic farm in Durham, CT. Shadle farm which is owned by the restaurant's owner composts 100 percent of the waste from the business. The farm runs 100 percent on solar energy and is heated by Connecticut made vegetable biodiesel. All the compost from the restaurant is used to fertilize the garden for the ingredients grown on farm. Gzen also has a catering truck called Gmonkey which operates solely on Connecticut made biodiesel. 100% of all waste at Gzen is either composted or recycled. The interior design is from 100 percent reclaimed materials.

Chef Mark Shadle currently visits schools, teaching kids about sustainable business practices and organic vegetarian lifestyles.

As part of their green initiative, Gmonkey and G-Zen both play an important role in the larger vision and sustainable branding of their "G" vision. Launched in May 2012, Gmonkey became the Nation's First All vegan and sustainable mobile food truck.

Gmonkey runs on 100 percent Bio fuel made from recycled vegetable oil that is produced locally in Connecticut. Gmonkey serves organic and vegan food that incorporates seasonal ingredients that are grown either at Shadle Farm in Durham or other local organic farms nearby.

Horst Engineering
East Hartford, CT

Execute changes that reduce annual energy or water consumption rates by more than 15%; implement clean energy generation projects utilizing fuel cells, solar, geothermal or wind power; and donate significant time or resources to assist with environmental projects.

Horst Engineering and sister company, Thread Rolling, Inc., are stewards of the environment. Horst’s 2008 investment in a solar PV electric power system has paid huge dividends. 2012 was a record year for their solar production. They generated 48,196 kilowatt hours (kWh) of clean energy at their 7,000 sq/ft 41 Cedar Street plant.

Their 128 rooftop solar panels provided 46% of the power used by the company. The system has been live for four full years and they have generated a total of 176,264 kilowatt hours (kWh) of clean energy through 2012. The solar system was part of a renovation that expanded their capacity while minimizing their environmental impact.

Through their membership in 1% for The Planet, they support 20+ environmental non-profits including the Appalachian Mountain Club, Connecticut Forest & Park Association, and Riverfront Recapture.

NRG Energy, Inc.
South Norwalk, CT

Adopt a vacant lot, park, community garden, stretch of highway, or beach for a year; sponsor a river, beach, or neighborhood clean-up day; implement habitat enhancements for fish or wildlife on public or private property; voluntarily contribute significant time or resources to environmental instructional programs, and donate significant time or resources to assist with environmental projects.

The Norwalk Harbor Station econrg project program funded two students to participate in the Earthplace Nature Center Environmental Internship program. The program is designed to introduce high school and college students to real life environmental sampling, analysis and reporting under the direction of the scientists at the Nature Center. All work is documented and QA/QC performed with laboratory work done at a state certified environmental lab. An annual report is provided by the interns at the Norwalk State of the Harbor address.

Each year NRG employees participate in the Earth Day Harborview marsh and beach cleanup effort. Employees offer their time and labor to collect flotsam and trash that wash ashore during the year. NRG offers the use of their heavy equipment for moving large items. In 2012 volunteers helped collect and properly dispose of a 40 cubic yard dumpster full of trash from neighboring beaches and marsh.

NRG helps fund the Environmental Student Detective Program in Norwalk. This program teaches students to use environmental indicators collected around the Norwalk Harbor to locate potential illegal contamination and broken sewage pipes from an aging infrastructure.

Using a special remote camera system the students can pin point the source of pollution. To date students have located and stopped seven major sources of contamination into Norwalk Harbor and Long Island Sound with a known and measurable improvement to the health of the ecosystem.

NRG employees planted a wildlife sunflower garden strip over 1300 feet long along the property line to attract beneficial wildlife and provide natural food for them. The sunflowers were a special variety grown specifically for the high concentration of oil and other nutrient rich components beneficial to wildlife. Sunflowers were enjoyed by honey bees as well as many other types of bees, butterflies and a variety of birds, squirrels, turkeys, and deer in addition to the beauty it provided to neighbors and those passing by. This garden was watered from rain water collected by employees.

A Diamond Back Terrapin Turtle Restoration Project was recently imitated. A large population of Diamond Back Terrapin Turtles would nest along both sides of the 1/2 mile long access road to the plant, however recent red fox and raccoon populations have also increased. The fox and raccoons dig up the turtle eggs thereby preventing them from hatching. There have been no successful turtle hatching on site for five years. This year, in conjunction with the SoundWater Environmental staff, a program to protect the turtle eggs was imitated.

NRG employees keep watch for the nesting activities which typically take place over a 2-3 day period each year.
When nesting activity is noted, an immediate call to the SoundWater Environmental staff is made and protective cages are placed over the turtle nests.
In addition, some eggs are harvested for incubation in a controlled environment with turtles to be released back into the environment when healthy and stable.

NRG's Norwalk Harbor has adopted a garden at a local street intersection in an area of the city that doesn't typically have many flower gardens. It provides a little natural color and beauty to the neighborhood.

PerkinElmer Health Sciences, Inc.
Shelton, CT

Execute changes that reduce annual energy or water consumption rates by more than 15%; promote or sponsor a company-wide or facility-wide employee commute program; certify to ISO 14001; reduce or eliminate the use of elemental mercury or products containing elemental mercury; document and implement a facility-wide pollution prevention plan; implement recycling specifications for construction and demolition waste in state or municipally funded building projects; and donate significant time or resources to assist with environmental projects.

PerkinElmer Health Sciences, Inc., has implemented a variety of energy conservation efforts, programs and plans in the company. Among them are energy conservation and reduction efforts through the retrofit and installation of high efficiency lightning and occupancy throughout the site; installation of high efficiency "green" chillers that utilize non-CFC refrigerants and variable speed electric drives; and installation of a plate and frame free cooling unit to curtail use of chillers during spring and fall for building cooling. The company provides commuter programs to its employees by offering Easy-Ride commuter vans and developed a "Transportation Match" database. The company is a recipient of the ISO 14001 Environmental Management Systems Certification as well as the OHSAS18001 Health and Safety Certification.
Currently, PerkinElmer has a Pollution Prevention Plan which has eliminated elemental mercury from manufactured products.
Additional efforts include the replacement of five residual oil boilers with high efficiency natural gas units thereby drastically cutting emissions and energy usage; and the deployment "For the Better Day" volunteer community betterment projects such as the Shoreline cleanup.

Philson, Inc.
Watertown, CT

Execute an innovative purchasing program that promotes the procurement of recycled and environmentally preferable products.

Philson held its 10th annual river clean-up, this year offering employees an opportunity to participate during work hours. Philson is also an active participant in the North East Utility Process Re-engineering for Innovation and Manufacturing Efficiency (PRIME) program. The idea behind PRIME is to use Lean principles to reduce solid and hazardous wastes and increase energy efficiency. Typically a 10% gain of production capacity is achieved with the same energy usage.

United Steel, Inc.
East Hartford, CT

Execute changes that reduce annual energy or water consumption rates by more than 15% and successfully implement an innovative and unique pollution prevention plan or recycling program that generates an environmental benefit.

United Steel installed Sonical fuel treatment systems on two of their diesel powered trucks. The units have produced significant fuel savings but most importantly have reduced the overall idle time emissions significantly. This is a critical element in the industry as the company logistically moves large pieces of steel from trailers to job site. United Steel’s overall improvement for the test period exceeded a 19% efficiency improvement in overall diesel fuel usage. The company plans to expand the program by installing 4 more units on the remaining fleet over the next several months.

A second significant improvement incorporated by the was the transition from paper drawings to the use of laptops in the fabrication shop. The company has eliminated hundreds of thousands of sheets of blueprints annually by making this significant change.

Westinghouse Electric Company, LLC
Windsor, CT

Execute changes that reduce annual energy or water consumption rates by more than 15%.

Two projects have led to approximately 20% reduction in water use at the Westinghouse Electric site in Windsor. The first project was started as part of their ISO 14001 targets and objectives to reduce electricity and water usage by their guide tube cleaning system. This system consists of two heated rinse tanks and two heated detergent tanks.

The rinse tanks were overflow tanks whose overflow went directly to the facility pre-treatment system. To reduce the amount of water being used, the overflow from the final rinse tank was re-directed and used as feed water for the rough rinse tank. Therefore, instead of using 4 gallons of water per minute the system now uses 2 gallons per minute. Procedures were modified so that water flow was shutdown at the end of each cleaning cycle and not restarted until the next cycle thereby saving additional water. Electricity needs were also reduced because the overflow water from the final rinse tank, which now feeds the rough rinse tank, is already at temperature and no longer needs to be heated. In addition, instead of having the overflow water from the rough rinse tank go directly into the waste water system, it first goes through a heat exchanger to preheat the cold DI water used to feed the final rinse tank.

The second project was part of a KAIZEN event to improve the cycle time throughout the end plug machining area. It was determined that if the end plugs were cleaned within the machining area instead of in a large cleaning area on the other side of the facility the end plug cleaning lead time would be greatly improved. A small cleaning system was designed for the area. That design consisted of three approximately 1/2 gallon cascading unheated rinse tanks and about 1/2 gallon heated detergent tank.

The feed into cascading rinse tanks is <1 gallon per minute. This is compared to two (2) 28 gallons heated rinse tanks in the old cleaning system both of which were fed at a rate of two (2) gallons per minute.

The direct savings in water is three (3) gallons per minute and much less electricity demand because the rinse tanks are unheated and the detergent tank is used less.


GreenCircle Award Recipients | GreenCircle Award Program

Content Last Updated on November 22, 2013