The factory has met the Environmental Protection Agency’s Energy Star Challenge for Industry by reducing its energy intensity by 37.8% within four years.
By meeting the challenge, the plant has averted more than 3,800 tons of greenhouse gases per year and saved enough energy to power more than 500 homes.
“We are extremely proud of achieving the Energy Star Challenge after four years of hard work. This certification validates the commitment that the Duffield plant and Tempur-Sealy have made to reducing our energy footprint and protecting the environment,” said Alex Lupi, director of operations at the facility. “Greg Robinson, our maintenance manager, and Charles Johnson, our EH&S manager, took ownership of the program and coordinated all benchmarking and improvement activities. I am also very pleased to reduce our environmental footprint in the community that provides us with such a strong and dedicated workforce.”
What is the Energy Star Challenge?
The Energy Star Challenge for Industry is a national call to action to improve the energy efficiency of America’s manufacturers by 10% or more. By taking the Energy Star Challenge, manufacturing sites set a goal to reduce their energy intensity by 10% within five years.
How did the plant meet the challenge?
In order to meet the Energy Star challenge, the factory performed a detailed analysis of its energy consumption. This analysis generated a roadmap of improvements and investments, including variable speed chillers; new LED lighting with daylight harvesting and occupancy sensors; high-efficiency, variable-speed air compressors; installation of a “cool roof;” an integrated building control system; and large, high-volume, low-speed fans throughout the facility.
What else has the plant achieved?
The Duffield plant is a landfill-free facility and holds the ISO 9001 Quality Management System certification, the ISO 14001 Environmental Management System certification and the OHSAS 18001 Occupational Health and Safety certification.
In addition to these energy savings, in 2019 the plant also in-sourced certain manufacturing functions, resulting in the elimination of more than 1.1 million truck miles per year.