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Brother Industries, Ltd. [Japan]
Cutting CO2 emissions by about 410 tons annually with solar power generation systems and energy-saving measures
Transparent panels for natural lighting embedded in the roof
A fan used for the air circulation system
Brother's Kariya Manufacturing Facility undertakes the R&D and production of industrial sewing machines and machine tools as well as indirect services. New buildings (Manufacturing Facility Buildings Nos. 4 and 5) featuring various energy conservation measures were completed and started operation in April 2009. The main energy conservation measures are shown below. Immediately after the buildings came into service, additional measures were taken, including installing pull-string switches for respective lighting equipment in the office to ensure that lights are turned off when not in use, thereby conserving more energy.
<Major energy-saving measures at the Kariya Manufacturing Facility>
- Insulated walls and insulated windows are employed, and the roof is coated with insulating paint, to keep indoor temperatures low when outdoor temperatures go up.
- The roof is embedded with transparent panels for natural lighting.
- Inverter-driven compressors are used.
- A system has been introduced to circulate air with fans installed on the ceiling or in high locations on the wall. This system is designed to prevent warm/cool air created by air conditioners from rising and to stabilize indoor temperatures so as to maintain precision in assembly and processing.
Next to the new buildings is located a solar power generation system with the capacity of about 100 kW. This system is expected to reduce about 410 tons of CO2 emissions per year at this manufacturing facility. A solar power generation system of a comparable capacity has been running at the Mizuho Manufacturing Facility since 2002. These solar power generation systems generated a total of 231 MWh of electricity in FY2009 (April 1, 2009-March 31, 2010). The efficiency of the solar power generation system at the Kariya Manufacturing Facility is about 18% higher than that of the Mizuho Manufacturing Facility.
Brother International Corporation (U.S.A.) [North and South America]
Taking various measures to significantly reduce energy consumption
A jumbo-sized fan installed on the ceiling of the warehouse
Roof materials that reflect sunlight
Brother Tennessee, a facility run by Brother International Corporation (U.S.A.) (BIC (USA)), uses a computer system to control the temperature and lighting of the entire facility, and thus reduce energy consumption. In FY2009 (April 1, 2009-March 31, 2010), in addition to an automatic lights-off system that was previously installed, the operating schedules of three cooling units were staggered, which reduced the annual electricity consumption by 702,000 kWh. Another energy reduction project completed in the autumn of 2009 was old roof materials being replaced with new materials which reflect up to 80% of sunlight to minimize heat absorption by the roof and reduce energy consumption for cooling the facility.
Next, the temperature settings in FY2010 (April 1, 2010-March 31, 2011) were raised during the summer months by three degrees (Fahrenheit) in the offices and four degrees in the warehouse areas compared to the temperature settings in such locations from the previous year. Also, a jumbo-sized fan was installed on the ceiling of the warehouse. During the summer months, the fan moves air to help employees feel more comfortable. During colder winter months, it pushes heated air down to the work floor and reduces the amount of fuel that the boilers consume.
These are but a few ways, BIC (USA) maintains continuous improvements towards reducing CO2 emissions.
Brother Industries (U.K.) Ltd. [Europe]
Reducing CO2 emissions by 112 tons with seven measures
In FY 2010, Brother Industries (U.K.) Ltd. (BIUK) took seven measures to increase energy efficiency, including replacing old, dirty skylights with clear skylights, installing an inverter power supply in the toner extraction process, as well as installing occupancy sensors for lighting and timers for gas heaters. BIUK successfully reduced CO2 emissions by 112 tons.
Old skylights before renovation
Factory lit more brightly thanks to new skylights
Brother U.K. Ltd. [Europe]
Winning the Queen's Award for significant reduction in environmental impact
Call center before the LED lighting system was installed
Call center with the LED lighting system
Brother U.K. Ltd. (BUK) has been carrying out various activities to continually reduce environmental impact.
A project in FY2009 (April 1, 2009-March 31, 2010), enabled the staff team, which was split between two separate buildings, to work in a single building and the office on the second floor was extensively renovated. During this renovation, priority was given to introducing highly energy-efficient devices. Lighting with occupancy sensors was introduced, and various apparatuses including fluorescent lamps, boilers, and vending machines were replaced with highly efficient models. In FY2009, BUK reduced CO2 emissions by 53 tons, electric power consumption by 12%, and paper consumption by 40% year-on-year. In FY2010 (April 1, 2010-March 31, 2011), BUK introduced LED lighting in the call center on the first floor to further reduce energy consumption by 79%. The LED lamps are long-lasting, contain no mercury or heavy metals, and are easy to recycle.
These activities have helped BUK halve energy consumption over the past five years and eliminate landfill waste via extensive recycling efforts. In April 2011, BUK won the Queen's Award, which is the most prestigious award in the UK. BUK remains fully committed to working on energy-saving measures.
Brother France SAS [Europe]
Introducing double-decker truck trailers for the benefit of customers and the environment
Cargo loaded in two tiers
In cooperation with a logistics company, Brother France SAS introduced double-decker truck trailers to meet the needs of business partners, increase transportation efficiency, and reduce CO2 emissions. This resulted in a CO2 emissions reduction of 46% compared with ordinary trailers
Zhuhai Brother Industries, Co., Ltd. [Asia / Middle East]
Improving CO2 emissions reduction activities to become a model factory of energy conservation
Zhuhai Brother Industries, Co., Ltd. has reduced its electric power consumption by introducing inverter compressors and replacing conventional lighting with high-efficiency lighting systems. In the cafeteria kitchen, gas consumption has been reduced by replacing gas rice cookers with electric rice cookers. In FY2009 (April 1, 2009-March 31, 2010), these efforts reduced CO2 emissions by 14.1% from FY2006 (April 1, 2006-March 31, 2007) levels. To reduce electric power consumption further, the company will employ inverter pumps for outdoor units of water-cooled air conditioners, install thermal insulation on the roof of the manufacturing facility, and replace oil transformers with dry transformers.
Brother Machinery Xian Co., Ltd. [Asia / Middle East]
Reducing CO2 emissions by about 32% from FY2006 levels by eliminating muda (waste)
The former Brother Sewing Machine Xian Co., Ltd. worked on saving energy by setting the target of reducing CO2 emissions by more than 8% from the FY2006 (April 1, 2006-March 31, 2007) levels by 2010. In FY2007 (April 1, 2007-March 31, 2008), compressors were replaced with high-efficiency inverter-drive models, and high-efficiency lighting was introduced on some production lines. In FY2008 (April 1, 2008-March 31, 2009), a campaign was carried out to eliminate air leakage, which saves energy consumed by compressors. In FY2009 (April 1, 2009-March 31, 2010), efforts were made to further reduce the electric power consumed by machining equipment during idling.
In FY2009, these efforts led to a CO2 emissions reduction of about 32% from FY2006 levels, far exceeding the target.
In June 2010, Brother Sewing Machine Xian Co., Ltd. merged with Xian Typical Brother Industries, Co., Ltd., to form a new company called Brother Machinery Xian Co., Ltd. While operations were being reorganized (such as adding parts procurement and inspection services), the company will continue to review muda (waste) and improve its energy conservation activities, and the CO2 emissions reduction targets for FY2010 (April 1, 2010-March 31, 2011) are expected to be achieved.
Brother Technology (Shenzhen) Ltd. [Asia / Middle East]
Cutting air-conditioning power consumption with 5,025 m2 of rooftop greening
The greening area is equivalent to more than 19 tennis courts.
Shenzhen City, China, which is characterized by a subtropical oceanic climate, is home to Brother Technology (Shenzhen) Ltd. (BTSL). In order to reduce top floor temperatures, BTSL launched rooftop greening of its manufacturing facility in August 2010.
BTSL planted Sedum lineare, a native species that is generally and widely used for rooftop greening, on the rooftop of its manufacturing facility (area: 5,025 m2). Sedum lineare, which is characterized by its beautiful vivid jade color, is a succulent plant that retains water in its leaves and stalks and is an evergreen perennial that is environmentally resistant. In addition to heat insulation performance, Sedum lineare is also expected to improve the ecological environment due to its capabilities to adsorb dust (about 8.5 times higher than that of other plants), absorb carbon dioxide, and release oxygen (about 30 times higher than that of other plants).
The rooftop greening has reduced the top floor temperatures by one to three degrees Celsius, and is therefore successfully reducing air-conditioning electric power consumption.
Brother Industries(Shenzhen), Ltd. [Asia / Middle East]
Working on energy conservation activities with all employees
Brother Industries(Shenzhen), Ltd. (BISZ) completed a series of activities to introduce various energy conservation systems and improve technologies, and then raised the eco-awareness of its employees and encouraged the reduction of muda (waste) on a voluntary basis throughout the company in FY2009 (April 1, 2009-March 31, 2010).
Specifically, the Brother eco point program was introduced and the General Manager explained the system. These efforts helped employees understand the significance of commitment and energy conservation action by every employee to reduce CO2 emissions. Employees started to suggest ways to conserve energy. Staircase lighting was replaced with lamps with occupancy sensors, and water heaters were replaced with energy conservation models one by one. The brightness in different workplaces was standardized, and a rule was established to measure brightness and review the lighting positions every time the workplace layout is changed. Employees were encouraged to ensure that lights are turned off when leaving the workplace, to activate the energy-saving mode in their PCs, and set the air-conditioning (cooling) temperature to 26ºC. Through these activities, all employees were fully informed of energy conservation, which has become part of their day-to-day work.
Taiwan Brother Industries, Ltd. [Asia / Middle East]
Managing the open/close timing of compressors, and eliminating unnecessary lighting equipment and power consumption
Taiwan Brother Industries, Ltd. worked on reducing electric power consumption by (i) managing the open/close timing of compressors in coating and washing machines and (ii) enabling compressors to be temporarily suspended by means of new air tanks built into the systems. These efforts helped reduce electric power consumption by 6.08 MWh annually. Lighting positions were also lowered (from 4.0 m to 2.8 m above floor level) to reduce the number of lights. The number of switches for lighting equipment was increased and the lighting area per switch was reduced; employees were encouraged to turn off unneeded lights whenever possible. These efforts reduced electric power consumption by 132 kWh annually.
Brother Industries Technology (M) Sdn. Bhd. [Asia / Middle East]
Successfully reduced electric power consumption by 7% via various energy conservation measures
In FY2009 (April 1, 2009-March 31, 2010), Brother Industries Technology (M) Sdn. Bhd. (BITM) worked on various energy conservation activities, and reduced electric power consumption by 7% year-on-year. Major activities included replacing hydraulic injection molding machines with electric models, removing old molding equipment (chillers), reducing electric power consumption via integration and reorganization of the manufacturing facility, removing old water-cooled air conditioners, replacing outdoor lighting equipment with energy conservation models, and reducing the number of indoor fluorescent lamps (checking and reviewing brightness).
Brother Industries (Vietnam) Ltd. [Asia / Middle East]
Significantly reducing electricity consumption through a series of small efforts
Application of an insulating film
In FY2009 (April 1, 2009-March 31, 2010), Brother Industries (Vietnam) Ltd. (BIVN) achieved the target of reducing electricity consumption by 30% year-on-year (in terms of sales ratio). In FY2010 (April 1, 2010-March 31, 2011), BIVN then set a target of reducing consumption by an additional 5% year-on-year, and started working toward the goal.
For lighting, 1,759 fluorescent lamps were replaced with energy-efficient models throughout the manufacturing facility during the one-year period. Continuing from the previous fiscal year, independent switches were also provided to allow fluorescent lamps to be turned on and off as necessary.
Regarding the use of air conditioners, a temperature rule was also established (27°C ± 3°C for cooling). Air conditioners of vacant rooms are turned off during lunch breaks, and all air conditioners are turned off five minutes before the end of work.
Insulating films were applied to all windows of the manufacturing facility to suppress the rise in indoor temperature, ventilation fans were installed near the ceiling for forced ventilation of hot air, and vinyl curtains were installed in the air-conditioned areas. All these efforts are intended to increase the efficiency of air-conditioning.
Measures were also taken to turn off unnecessary lights in the cafeteria and locker room, PC monitors in standby mode, and high-voltage lamps around the company. As a result, electricity consumption in FY2010 was reduced by 8% year-on-year, surpassing the target.
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