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    Challenges To Going Green In Manufacturing/Distribution ... Challenges To Going Green In Manufacturing/Distribution ... Presentation Transcript

    • Challenges To Going Green In Manufacturing/Distribution Facilities Track 4 Session 5
    • Paul Todd Merrill, PE, LEED AP Director of Sustainable Construction Clayco merrillp@claycorp.com 314.429.5100 2 Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
    • Abstract The US Green Building Council's LEED Green Building Rating System is the international standard for defining a new or existing green building however, large manufacturing and distribution facilities can struggle to meet the LEED metrics much of the time. These building types present a significant impact on the environment and many are self-defined as green, but few have been able to gain the official designation of LEED Certified. The presentation will focus on an overview of the LEED Green Building Rating Systems and specific examples of project challenges to obtaining LEED certification. In addition, the presentation will include a discussion of practical and economical energy saving ideas to incorporate into your facility to increase LEED credit potential, improve operational cost and reduce impact on the planet. Also provided will be an Energy Consumption Calculator to help you compare the effect of design choices. 3 Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
    • Agenda Green Building Progress to Date Overview of the USGBC - LEED Assessment System and new changes Challenges with USGBC - LEED and Manufacturing/Distribution Recommendations Energy Consumption Calculator Demonstration 4 Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
    • Clayco Green Building Progress Platinum Certified: 1 Project Gold Certified: 5 Projects Silver Certified: 4 Projects Certified Level: 16 Projects 5 Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
    • Starting Points Presentation with new construction focus Regional approaches/attitudes and capabilities differ across the country Heated/ventilated vs. conditioned space Process loads are unique to each project We represent one contractor’s opinion Each client/project is unique Not here to preach why this is a good thing 6 Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
    • Starting Points Environmental Impact of Manufacturing/Distribution Facilities Energy use/water use Waste generation/packaging Transportation impact Material quantities Site impact and land use 7 Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
    • What We See and Hear in the Manufacturing/Distribution Marketplace… Increased commitment to going green 75 – 90 % of recent opportunities consider LEED certification or Sustainable Measures Clients are becoming more educated Industry wants to be GREEN just not sure how to do it! Green practices in place – but just not touted as such Still a lot of misconceptions 8 Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
    • What We See and Hear in the Manufacturing/Distribution Marketplace… “We have implemented high efficiency process equipment, but get no LEED credits!” “Not going green” is the exception Energy savings results from a business case perspective Results = Better, Higher Quality Buildings Others will follow your sustainable lead! 9 Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
    • Overview - USGBC LEED Rating Systems Internationally recognized green building certification system using third-party verification that a project was designed and built using strategies aimed at improving performance across all the metrics that matter most: Energy savings Water efficiency CO2 emissions reduction Improved indoor environmental quality Stewardship of resources and sensitivity to their impacts. 10 Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
    • USGBC LEED Progress to Date 19,957 USGBC member organizations 2,476 commercial LEED certified projects 19,524 commercial LEED registered projects 91 countries with LEED projects 4.2 billion square feet in process 81,155 LEED accredited professionals 11 Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
    • Overview - USGBC LEED Rating Systems LEED BD&C – Building design and construction (old LEED NC) LEED EBOM - Existing buildings: operations & maintenance LEED ID&C – Interior design and construction (old LEED CI) LEED core and shell, LEED for schools 12 Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
    • Overview - USGBC LEED Rating Systems LEED v3.0 – LEED 2009 newest version Each system includes prerequisites and credits 100 point system + 10 bonus points 4 certification levels Certified - 40 Points Silver - 50 Points Gold - 60 Points Platinum - 80 Points You Don’t Have to Do Everything! 13 Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
    • LEED Credit Categories Sustainable Sites – 26 points possible Water Efficiency – 10 points possible Energy & Atmosphere – 35 points possible Materials & Resources – 14 points possible Indoor Environmental Quality – 10 points possible Innovation in Design – 6 points possible Regional Priority – 4 points possible 14 Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
    • 15 Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
    • 16 Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
    • LEED Recent Changes – LEED v3.0 Weighting of priorities of credits Emphasis on sustainable sites and urban developments – 26% of credits Increased water conservation efforts – 10% of credits Increased energy efficiency and carbon production reductions – 35% of credits Regional priority credits 17 Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
    • Easier LEED Points For Manufacturing/Distribution Sustainable construction activities Erosion and sediment control measures Air quality management and cleanliness Construction waste management and diversion Site logistics and storm water issues – except vegetative “green” roofs 18 Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
    • Easier LEED Points For Manufacturing/Distribution Reduced parking capacity and preferred parking Reduced heat island effect - roof Domestic water use reduction measures – landscaping and plumbing fixtures Use of regional and recycled content materials Materials and finish selections 19 Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
    • Challenging LEED Points For Manufacturing/Distribution Site and location challenges – urban vs. rural Alternative transportation measures – bike racks & showers, public transportation access Maximize open space Restoration of native vegetation Reduced heat island effect, non – roof hard surfaces 20 Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
    • Challenging LEED Points For Manufacturing/Distribution Use of on-site renewable energy sources Enhanced building systems controls for tracking and monitoring of energy use and outdoor air monitoring Use of salvaged (used) building materials Use of rapidly renewable and certified wood materials 21 Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
    • Challenging LEED Points For Manufacturing/Distribution Enhanced HVAC Systems and refrigerants Occupant controllability of lighting/thermal comfort accessible controls Natural illumination to meet credits Innovation in design credit limitations – limited to 6 total; 1 for LEED AP on Project; only 3 points allowed for exemplary performance 22 Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
    • Challenging LEED Points For Manufacturing/Distribution Energy use and process load challenges Can be low energy users to begin with Process loads can be tricky Energy loads must be “modeled” Up to 19 points can be “available” in this LEED category Energy modeling rules and the building type make this challenging 23 Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
    • Challenging LEED Points For Manufacturing/Distribution Energy use credits – regulated modeling Determine baseline energy use from ASHRAE 90.1-2007 standards Determine actual design energy use from selection of envelope, HVAC, Lighting, domestic water heating and process loads Percent cost savings from actual design to baseline determines available LEED points 24 Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
    • Challenging LEED Points For Manufacturing/Distribution Project X Energy USE Pumps Motor Loads Energy Use 10^6 Btu/yr 18000 Cooling Systems 16000 14000 Lighting Systems 12000 Power Devices 10000 8000 Heating Systems 6000 4000 Process Loads 2000 0 Basecase Proposed Design 25 Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
    • Challenging LEED Points For Manufacturing/Distribution Larger buildings (over 150,000SF) are required to be modeled with more efficient baseline performance systems per ASHRAE appendix G All “conditioned spaces” in the proposed design shall be simulated as being both heated and cooled, even if none is to be installed. 26 Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
    • Challenging LEED Points For Manufacturing/Distribution “Conditioned Spaces” are defined as cooled space, heated space, etc. Heated space in a building is considered if the output capacity of the system relative to the floor area is greater or equal to: Heating Output (Btu/Hr*SF) Climate Zone 5 1&2 10 3 15 4&5 20 6&7 25 8 27 Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
    • ASHRAE 90.1-2007 Climate Zones 28 Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
    • Challenging LEED Points For Manufacturing/Distribution “Process Loads” must be identical for both baseline and actual design. HOWEVER, Exceptional Calculation Method (ECM) can be used to document measures that reduce process loads. Exceptional Calculation Method can be used when no simulation program is available that adequately models a design, material, or device. 29 Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
    • Challenging LEED Points For Manufacturing/Distribution Documentation must include listing of assumptions for both baseline and actual design and theoretical or empirical information supporting the assumptions. ASHRAE 90.1-2007 appendix G2.5 is the reference standard 30 Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
    • 31 Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
    • Recommendations for LEED Points…Or Just Good Practices Implement energy efficiency improvements – envelope, HVAC systems, lighting systems ASHRAE Advanced Energy Design Guideline for Warehouses is a great resource Creative approach to the exceptional calculation methods – past data collection; work with equipment suppliers; documented process load efficiencies 32 Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
    • Recommendations for LEED Points…Or Just Good Practices Energy Efficient HVAC Systems VFD controlled exhaust ventilation systems Higher efficiency MAU and RTU equipment, chiller plant, drive units Passive Ventilation and Cooling Heat Recovery from process loads Energy recovery units Thermostatically controlled exhaust systems 33 Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
    • Recommendations for LEED Points…Or Just Good Practices Energy Efficient HVAC Systems 34 Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
    • Recommendations for LEED Points…Or Just Good Practices Energy Efficient Lighting Systems T-8 or T-5 fluorescent lighting systems Motion controlled lighting Daylight Harvesting Systems Foot-candle levels which do not exceed task requirements Centralized controls LED lamp sources Reflective interior surfaces Use task lighting where appropriate 35 Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
    • Recommendations for LEED Points…Or Just Good Practices Energy Efficient Lighting Systems 36 Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
    • Recommendations for LEED Points…Or Just Good Practices Energy Efficiency Building Envelopes Dock Seals Reflective Roofing Materials 37 Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
    • Recommendations for LEED Points…Or Just Good Practices Innovation in design credit ideas: Transportation/rail emission reduction measures Shipping/delivery reduction measures Reduced packaging efforts - waste stream reductions Supply chain perspective – upstream and downstream Establish green cleaning policies Establish A green education plan 38 Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
    • Recommendations for LEED Points…Or Just Good Practices Transportation/rail emission reduction measures Smarter Travel Better Vehicles Better Fuels Improve the efficiency of operations 39 Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
    • Recommendations for LEED Points…Or Just Good Practices Reduced packaging efforts - waste stream reductions 40 Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
    • Recommendations for LEED Points…Or Just Good Practices Establish green cleaning policies 41 Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
    • Recommendations for LEED Points…Or Just Good Practices Consider alternate green building assessment tools Green globes, energy star Embrace self – defined certification! 42 Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
    • Energy Consumption Calculator Excel spreadsheet tool Estimate of power consumption comparison for 2 scenarios Input data tabs - storage, pallet conveyor, case conveyor, sortation, automated vehicles, manual vehicles, picking/palletizers, lifts, building utilities Cost savings or KWHR savings results 43 Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
    • Energy Consumption Calculator 44 Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
    • Energy Consumption Calculator 45 Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
    • Energy Consumption Calculator 46 Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
    • Project Examples - Manufacturing/Distribution Facilities Anixter, Inc. Distribution Warehouse Alsip, IL 450,000 SF Logistics Distribution Warehouse 19,000 SF Office Area $16.5 M Construction Cost LEED NC Certified Design / “Actual” Construction Duration = 8-9 Months 47 Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
    • Project Examples - Manufacturing/Distribution Facilities Villa Lighting St. Louis, MO 222,000SF Distribution Center Urban Setting LEED NC v2.2 Registered 48 Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
    • Project Examples - Manufacturing/Distribution Facilities USPS - Troy, MI and Greenville, SC Bulk Mail Processing Centers LEED NC v2.2 Registered Projects Troy, MI – 150,000SF Renovation Greenville, SC – 200,000SF Addition; 58,000SF Renovation 49 Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
    • Project Examples - Manufacturing/Distribution Facilities General Mills Social Circle, GA 1,500,000SF Distribution Center LEED NC v2.2 Registered 50 Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
    • Key Takeaways General overview of the LEED rating system and new changes Sustainable measures may already be in place LEED challenges to manufacturing/distribution facilities Certification can be challenging but can be done! 51 Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
    • References www.usgbc.org – Further Understanding of the LEED Rating System and Case Studies www.energystar.gov – Great tools and resources for existing and new buildings www.ashrae.org/publications/page/1604 - Advanced Energy Design Guide for Warehouses Manufactures Websites 52 Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
    • Questions? 53 Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS