Professional

ENVIRONMENTAL PROTECTION AT OUR PRODUCTION SITES

Responsibility for environmental protection at LEDVANCE lies clearly with company management and is supervised by the EHS department which handles company-wide coordination and continued development. At individual plants, managers and their department heads are responsible for practical implementation. The plants receive support and advice from our environmental experts on energy, water, waste, chemicals and air pollution.

Environmentally sound production techniques in LEDVANCE factories help us achieve our objectives for environmental protection and cut production costs at the same time. To this end, we have implemented environmental management systems at our production sites, which are certified according to the international standard ISO 14001.

In order to give an insight into how our objectives for environmental protection are implemented into the LEDVANCE production process, we have collected a number of examples, showing how individual sites are striving to lower their environmental impact.

Objective

Energy-efficient halogen and LED lamps are produced at the site. For many years action plans have been in place to promote the careful use of resources, environmental protection and energy savings. At the Eichstätt plant a new energy center with a combined heat and power plant and a refrigeration plant is currently being constructed, which will save 4,000 tonnes of CO2.

Due to the substantial increase in the production of new energy-saving products, the energy demand at the plant has increased enormously. To reduce this increase, the Hoshin Kanri method was used which entailed defining energy targets and identifying various approaches to save CO2. Effective measures were agreed on and implemented by the relevant team.

Solution

The greatest single energy-saving measure at Eichstätt is the combined cooling, heat and power plant (CCHP) project.

The CCHP uses combustion to convert the chemical energy of the fuel into thermal energy and kinetic energy. Useful energy in the form of electricity and heat is produced to supply the site. At full load, the total thermal output of the CCHP is approximately 4.7 MW, of which 2.0 MW is electricity and 1.95 MW useful heat. The electricity is used predominantly to cover the basic load of the Eichstätt plant. The useful heat is used for heating during the winter months and for producing chilled water in the summer months by means of an absorption chiller. Conventional, power-hungry refrigeration units which would otherwise be needed can then be switched off.

By using waste heat for heating or cooling, the overall efficiency of the power plant can be as high as 84%. As a result, energy utilization of the primary energy source is around twice as high as for conventional thermal power plants that are used simply to generate electricity. Other benefits of the decentralized CCHP plant at the site is that there are no transmission losses from the power plant to the loads, no need to lay new power lines, and the load on the power grid is also reduced.

CO2 savings with the CCHP at Eichstätt are 4000 tonnes per year thanks to the coupled generation of electricity, heat and cooling. The CCHP was completed in January 2015, and the absorption chiller, with an output of 800 KW, went operational in April 2015.
In addition to the CCHP, a number of other steps have been taken to reduce the consumption of energy and resources.

  • The cooling towers have been extended so that potable water is no longer used for cooling purposes. The consumption of natural gas has been reduced by thermal recovery from the waste heat produced during the heating period.
  • Demand-based control of the intake and exhaust air is reducing the consumption of electricity and heating gas.
  • Higher feed temperatures for the compressors and machinery are reducing the cooling requirements and improving the efficiency of thermal recovery.
  • Frequency converters in the ventilation system and the cooling towers ensure that speeds are controlled on the basis of demand, further reducing power consumption.
  • Regular ultrasound analyses are performed to identify and eliminate leakages in the compressed air network. Compressed air losses are therefore lower, which again reduces power consumption.
  • Optimizing the acid release system and the neutralization system is reducing the volume of waste water and the costs of chemical preparation.
  • By replacing 2x 58 W T8 fluorescent tubes per luminaire with 1x 35 W T5 energy-saving tubes and using effective reflectors there have been savings of up to 70% in the power needed for the lighting.
  • Upgraded insulation for various system components has cut heat losses by 30%.

The combination of all these measures has greatly reduced the consumption of energy and resources at the Eichstätt plant and has therefore made a significant contribution to improving the sustainability of the production process.

Objective

The consumption of energy and water has to be reduced at LEDVANCE's Molsheim site in France.

Solution

We have reduced the consumption of gas by 23% over five years by replacing the burners on our high-performance production lines.

Moreover we have reduced the volume of water used for cooling systems by 69% by adopting a new technology (adiabatic cooling tower). And this has also allowed us to reduce the risk of releasing legionella bacteria into the environment and avoid the use of dangerous chemical products.

Consumption at the plant has been reduced by optimising the use of energy and water and by investing in new and more efficient technologies.

Objective

The reduction of hazardous substances in production is of great importance for LEDVANCE. For this reason, the LEDVANCE SYLVANIA plant in Versailles, Kentucky, strove for a solution to eliminate lead in all linear fluorescent lamps manufactured at the site. Furthermore the plant initiated processes to reduce energy consumption and the associated CO2 emissions.

Solution

In 2010, the glass plant in Versailles underwent a major furnace-rebuilding project, designed to completely eliminate lead from the glass used to manufacture linear fluorescent lamps. Using the new oxy-fuel glass melting technology, the site further managed to cut energy as well as resource consumption and save on NOx emissions. The natural gas usage could be reduced by 28 percent and NOx emissions by 80 percent. Above that the technology improves furnace performance and therefore saves about US$ 3 000 000 annually in energy costs.

To achieve energy reduction goals the Versailles plant was subjected to lighting upgrades. By installing lower-wattage lamps, more efficient systems, and lighting control technologies, the site managed to reduce energy consumption by 1 500 000 kWh annually while upholding the same lighting standards, avoiding 1400 tons of CO2 emissions from power plants.

INTERNAL MONITORING AND ENVIRONMENTAL ANALYSES

We regularly monitor our environmental management and conduct audits to test the progress made in environmental protection and ensure that it complies with the EHS guidelines. This monitoring and analysis is carried out by our EHS department. LEDVANCE uses these results to ensure that all relevant legal and other requirements are respected and to explore innovative ways of improving environmental protection at LEDVANCE. For environmental reporting we have globally implemented a web-based EHS software suite. Each LEDVANCE site exceeding a defined threshold in energy consumption, emissions or waste production is required to quarterly report its environmental figures.

Share page on Social Media