FACILITY UPGRADES RESULT IN REDUCTIONS IN ENERGY COSTS FOR ALPHARETTA COMPANY

Metcam implements Sustainable Manufacturing programs and reaps rewards

Case Study 2 // Alpharetta, GA // August 2010

Metcam, Inc. is a mid-sized manufacturing firm founded in 1989 in Alpharetta, Georgia, specializing in advanced metalworking technology.   Manufacturing capabilities at their 100,000 square-foot facility include laser cutting, punching, forming, hardware insertion, welding, powder painting, silkscreen printing and assembly.  Metcam has focused its manufacturing improvements on quality, environmental and lean manufacturing concepts.  The company has attained certification in both ISO 9001 and ISO 14001, which allows them to qualify as a supplier of high quality parts that meet international environmental and regulatory standards such as the RoHS and REACH requirements in the European Union.

As part of their ISO 14001 program implementation, Metcam identified the significant environmental aspects of their operations along with the associated environmental impacts from these activities.  The significant environmental impacts they identified included energy usage, natural resource consumption, and solid waste generation.  Metcam set specific objectives and goals for reducing their environmental impacts and began with an energy audit conducted in March 2009 by their electrical provider, Sawnee EMC.  From the twenty-two observations documented during the audit, Metcam prioritized three projects that held the most promise to achieve significant energy reductions and provide a solid return on investment. 

The first project was to improve facility insulation. Metcam replaced an aging roof with an insulated roofing membrane system consisting of a reflective white elastomeric membrane over a 1-inch foam insulating layer. The second project was to install energy efficient lighting. The facility used a combination of fluorescent and mercury vapor lighting.  By eliminating more than 100 400W metal halide lamps and installing T8 fluorescent lights, energy savings of 340,000 kWh per year were estimated. The cost of new lighting fixtures was minimized in areas where the existing fixtures could be converted to accommodate the new ballasts and lamps.  In addition, motion detection sensors were installed in areas that were not continually staffed.  Payback for this project was estimated at just under two years and the annual CO2 reduction was estimated at 240 metric tons. The last project was to consolidate and replace older, inefficient air conditioning units. Metcam replaced older air conditioning units with twelve energy efficient units linked to a sophisticated digital monitoring and control system. 

These projects were scheduled during the spring and summer of 2009, providing Metcam with additional cost savings from energy rebates and tax incentives available at that time. The positive impacts of these projects were noticed immediately by Metcam employees.  T8 lighting produced higher lumen levels and resulted in better lighting throughout the facility.  Another improvement was apparent soon after the new air conditioning systems were installed.  After balancing the output from the new units, zone temperatures became more consistent resulting in better working conditions for Metcam’s employees. 

Metcam continues to monitor their monthly electrical usage and is considering additional energy savings projects to further reduce energy consumption, lower CO2 emissions and further improve their environmental profile.  The facility’s electricity usage through the first quarter of 2010 was an average 8% lower than the previous year.  Metcam remains committed to the concept of Sustainable Manufacturing through implementation of their ISO 14001 program.  Their experience demonstrates that there is a business case to be made for sustainability based on direct cost savings, improved employee morale and the marketing benefits of environmental certification.

Metcam is a Charter member of the Partnership for a Sustainable Georgia, currently at the Silver Level of the program.