Judging from the advertising campaigns by major corporations these days, it seems they've all gone "green." That's the clichéd term synonymous with being environmentally responsible. The truth is, many of these so-called green initiatives are either driven by regulatory mandates or are manufacturers' attempts to win over the public with their corporate citizenship. Often lost in such self-serving cheerleading are the facts behind the cost-reduction potential of alternative energy in manufacturing operations.

To separate the wheat from the chaff, IndustryWeek asked James Lee, an associate professor in the Golisano Institute for Sustainability at the Rochester Institute of Technology, about the pros and cons of alternative energy usage in manufacturing. As a member of the research faculty, Lee is a fuel-cell team leader responsible for coordinating all aspects of fuel-cell research. He also conducts analysis of industrial processes to determine the feasibility of energy-savings modifications, and works with industrial suppliers to create products that minimize lifecycle costs through sustainable design practices. Previously, Lee served as a senior research engineer within General Motors Fuel Cell Activities.

IW: What are some of the main types of alternative energy being used in manufacturing applications?

Lee: The energy used by manufacturers can be broken down into two broad categories: electricity and thermal energy (heat). Manufacturing companies are working in both of these areas to reduce consumption and expand the use of alternatives to fossil fuel. In addition to working with utility companies to increase the supply of electricity from renewable sources, many manufacturers are investing in combined heat and power (CHP) systems that produce both electricity and heat for their manufacturing processes. CHP systems increase energy efficiency by making better use of the energy. Using a CHP system also enables companies to produce electricity directly from alternative fuel sources such as biofuels, hydrogen and solid municipal waste. Companies are also burning alternative fuels directly in boilers to produce the process heat.

IW: What types of manufacturers are utilizing alternative energy?

Lee: Industries such as agriculture, food processing, metal refining, paper manufacturing and the chemical industry are heavily involved in developing alternative energy strategies, but industries like product assembly and printing are not as engaged.

IW: Where is the greatest growth potential for alternative energy in manufacturing operations?

James Lee, associate professor in the Golisano Institute for Sustainability at the Rochester Institute of Technology

Lee: The greatest growth potential is in industries that have a high energy cost to raw material cost ratio. As the cost of conventional sources of energy increase, the economic pressure on firms to find low-cost energy alternatives will also increase, resulting in more companies investigating and investing in alternative energy.

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