Efficient

Happily, in our manufacturing locations often the best thing for the bottom line is the best thing for the environment. We ponder ways to save resources and energy, and explore new technologies that can improve the manufacturing process. Some of these even deliver double results, saving energy while increasing production.

A short list of some of our areas of efficiency includes:

• Biodiesel
• Compressed Air
• Shrinkwrap
• Rail transportation
• Improved tufters, becks, boilers and lights
• Cogeneration

Below is a little more information on each of these initiatives:

Biodiesel

It might not smell as good as using “post-french-fry” oil, but in mid-2004, Mannington started using B5, a 5% biodiesel blend, in our diesel fueled trucks and fire system pumps.

B5, which adds soybean oil to traditional diesel, uses a renewable resource grown in the USA. This fuel helps reduce dependence on foreign oil and burns clean, reducing harmful air emissions. It also helps make fuel pumps and injectors last longer due to increased lubrication, and switching doesn’t require any modifications and or negatively impact engine performance.

In 2005, we will evaluate the year’s performance of the 5% blend, to determine if it’s possible to increase the percentage.

PS: Biodiesel is being used in home heating systems, too. If your furnace burns oil, ask about biodiesel.

Compressed Air

Sometimes what looks like the smart idea isn’t. For example, we use compressed air for different things throughout the facility. It seemed like compressing all the air we needed in one location would be the most energy-efficient way to, well, compress air. But we did a little research and crunched some numbers, and it turns out it is more efficient to compress the air at the place where we need it. It seems the energy loss of piping the air across the facility floor was enough to make the difference. While we were at it, we rerouted the heat created by the compressors into the ductwork, so in colder months we can make use of it rather than vent it to the outside.

Shrinkwrap

At Mannington, we make durable, long-lasting product. So our carpet should be able to get from us to you without five pounds of packaging for each pound of carpet. We tested this, and it’s true. Instead of using excessive packaging, we can ship our carpet coddled in shrinkwrap, and it arrives safe and environmentally sound. This uses ninety percent less materials by weight – quite a significant savings.

Rail Transportation

Approximately 85% of VCT is limestone. It’s heavy, and it has to be shipped from Connecticut to our New Jersey manufacturing facilities. That would add up to a lot of diesel fuel, and many loud traffic-clogging trucks. So we took a different track.

We repaired an old rail line near the plant to ship limestone from Connecticut in boxcars – and annual fuel savings are some 290,000 gallons. Not to mention there is less congestion and less wear on the roadways.

Improved tufters, becks, boilers and lights

Much like trading in an old car on the latest model with heated seats and a navigation system, upgrading our equipment results in not only improved performance but in significant energy savings. In the last few years, we have invested in high-speed tufters, Bruckner Becks, fluorescent lighting systems and modern boilers.

Cogeneration

Our new high efficiency cogeneration system supplies complete electrical and steam energy to our Salem site. This new system utilizes state-of-the-art natural gas-fired engine technology to generate electricity for the manufacturing and office facilities. Excess heat from the generation process is being recovered and utilized as needed for process and building heat. The combined heat-power capability of this system is substantially more energy efficient than traditional utility generation technology, and the system utilizes clean burning natural gas as its only fuel source. The net impact of this system will lower our energy consumption by over 100,000 mmBtu’s per year.

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