The Schneider Electric/Square D Lexington plant is committed to protecting the environment. The recipient of ASSEMBLY’s 4th annual Assembly Plant of the Year award has been ISO 14001 certified since 2003.

“To drive continuous improvement in our environmental program, we set out an aggressive plan to reduce internal waste from assembly processes and reduce consumption of utilities,” says Bob Spence, plant manager.

In 2005, a separate team was set up to review both short- and long-term utility opportunities. The utilities reduction team met twice a month to brainstorm potential opportunities with its heating, ventilating and air conditioning (HVAC) suppliers. It investigated new technology within the HVAC and lighting industry. The team evaluated cost savings and generated business cases for management approval.

The ambitious effort resulted in numerous changes in the consumption of electricity and natural gas. For instance, the plant:

*Implemented T8 lights for reduced consumption in 2006.

*Installed variable-frequency drives on boiler feed pumps.

*Implemented improved shut down procedures for weekends to reduce utilities.

*Installed motion-sensing lights in key areas.

*Installed automated penthouse damper controls.

*Purchased two new gas-fed boilers to replace old, inefficient units.

*Replaced insulation on steam lines.

*Implemented steam trap maintenance with an outside vendor.

*Increased electrodeposition paint line speed for capacity and reduced gas usage.

*Replaced the roof of the building to improve heat loss and leakage.

In addition, the plant eliminated hexavalent chrome in its plating process, created a waste minimization team, and implemented an ink cartridge recycling process. Use of returnable packaging and containers also help the facility maintain its ISO 14001 certification.