Energy Management and Usage
Energy is a key resource in the production of Cooper tires. In most cases, it is generated from fossil fuels, a natural resource, and results in atmospheric emissions, including greenhouse gas emissions. Consequently, Cooper recognizes our responsibility to manage energy and its usage wisely.
Formal energy management systems have been established in Cooper’s U.S. tire plants. The systems allow Cooper to use energy more efficiently by using key metrics to examine daily performance, analyze trends that highlight opportunities for improvement and implement energy-saving projects. Cross-functional energy teams were formed to identify opportunities and implement suggestions in each plant. A number of projects have been identified and implemented, resulting in significant energy, greenhouse gas emission and cost savings.
Energy Star Program
Cooper has been designated as an “Energy Star Partner” by the U.S. Department of Energy and U.S. Environmental Protection Agency. Cooper is one of only two tire manufacturers to be designated an Energy Star Partner. In applying for the designation, Cooper made a fundamental commitment to protect the environment through the continuous improvement of its energy performance. Specifically, Cooper agreed to measure and track the energy performance of its facilities, develop and implement a plan to achieve energy savings, communicate the importance of energy efficiency to employees and the public, and support the ENERGY STAR Challenge, a national call-to-action to help improve the energy efficiency of America’s commercial and industrial buildings by 10 percent or more. Improved energy efficiency not only saves money and conserves natural resources, it also reduces greenhouse gas emissions. The partnership is another indication of Cooper’s commitment to environmental protection.
Indiana Distribution Center - Gold LEED Certification
Cooper’s new 804,000-square-foot warehouse and distribution center in Franklin, Ind., has earned Gold certification status under the Leadership in Energy and Environmental Design (LEED) Green Building Rating System administered by the U.S. Green Building Council. The system is a voluntary, consensus-based standard to support and certify successful green building design, construction and operations. LEED certification is attained by incorporating “green” features into the design and construction of the building.
Unique attributes of the Franklin facility include a white thermoplastic polyolefin roof, which offers a longer warranty, requires less maintenance and reflects heat; heavily insulated walls, which provide a 42-percent improvement in energy efficiency compared with standard walls; high efficiency lighting with occupancy sensors, which reduces electrical usage up to 50 percent; low-flow water fixtures, which should provide a 30-percent reduction in potable water usage; a unique lawn and landscape design, which reduces storm-water runoff and uses no irrigation; and an all-concrete parking lot, which reduces ongoing maintenance costs.
Cooper is one of only two tire companies to boast possession of a LEED-certified building. Moreover, the Franklin facility is the largest gold-LEED-certified distribution center in the U.S., and one of the largest LEED-certified buildings in the world.
Greenhouse Gas Emissions
Greenhouse gas emissions have become an environmental concern due to the perceived potential to cause global warming. Greenhouse gases are directly emitted from fossil fuel combustion. During the life-cycle of a tire, greenhouse gases are emitted during the raw material production and delivery phase, the manufacturing phase, the tire delivery phase, the tire use phase, as well as the scrap tire management phase. The predominant phase for greenhouse gas emissions is the tire use phase due to the fuel consumed by the vehicle.
Cooper is concerned about the greenhouse gas emissions from our operations. Greenhouse gases are directly emitted from fossil fuels consumed at Cooper’s plants and indirectly from electricity usage. With the recent implementation of formal energy management systems at its U.S. tire plants, Cooper is now able to monitor and reduce greenhouse gas emissions from its operations.
Cooper Fleet
Cooper operates a fleet of tractors and trailers to transport its products to customers, and to transport finished goods, equipment, and raw materials between facilities. Numerous efforts are made to minimize fuel usage and maximize efficiency as the fleet travels millions of miles each year. For example, Cooper works to haul fully-loaded trailers and avoid empty miles. In addition, routes are strictly planned and controlled, and fuel is purchased through one distributor to ensure consistent quality and mileage.
Each tractor is equipped with an auxiliary power unit (APU) that provides power to the tractor cab during the driver's mandatory 10-hour-per-day break periods. It provides power for heating and cooling, lights, and entertainment systems. This avoids idling the tractor engine to provide power during these periods. The APU uses one tenth as much fuel as the idling tractor, which conserves approximately 500 to 600 gallons of fuel per week for the fleet. Cooper has ordered new tractors which will have battery–powered APUs. The batteries will be recharged by the tractor engine during operation. This will conserve approximately 35 gallons of fuel per week for the fleet. In addition, the new tractors will emit less nitrogen oxides and particulate matter to the air than the current tractors.
Cooper has installed farings on two of its trailers on a trial basis. The farings improve the wind flow around the moving trailer and reduce the drag. As a result, the farings are expected to reduce fuel consumption by at least 5 percent. If successful, farings will be installed on additional trailers.
Energy Efficient Lighting
Cooper operations currently occupy over 22 million square feet of floor area in factories, warehouses, and offices around the world. This is equivalent to approximately 380 American football fields, one square mile, and two square kilometers. An estimated 41,000 light fixtures are used to provide lighting for employees to work in these areas. Assuming that each light is 455 watts and is switched on 80 percent of the time, the lights consume as much electricity in a year as about 11,800 homes.
Cooper has been replacing older style lights in select locations with new, more energy efficient lights. A typical project involves replacing 500 lights in a portion of a warehouse resulting in a 37 percent energy reduction. In addition, in some areas, motion and daylight sensors are being installed so that lights are used only when needed. Additional lighting projects are being planned.
Texarkana, Ark. Plant Earns 'Save Energy Now' Award
Cooper’s Texarkana, Ark., plant recently received a "Save Energy Now" Award from the U.S. Department of Energy (DOE). The facility is one of just 93 in the U.S. to merit an Energy Saver award. The award is presented to plants that achieve more than 75,000 million British thermal units or more than 7.5 percent in total energy savings.