A LIFELONG JOURNEY

Not too long ago, the concept of ?going green? was thought of as a fad. Not anymore. The move toward increased energy efficiency and environmental responsibility in the welding industry now demands a closer look at sustainable manufacturing processes.

Recently, Lincoln Electric (Cleveland, OH) rolled out its new Green Initiative Awareness Program, but the company has actually been making strides towards environmentally friendly initiatives, specifically, reducing energy consumption, for a number of years.

This welding equipment manufacturer has implemented simple energy management practices that include using less electricity to light the building, managing ventilation systems to use less natural gas, re-using waste heat from various processes, improving building insulation, and rethinking its production lines to make the use of energy more efficient.

Basic efforts, like turning machines off when they?re not in use and using sensors to determine when equipment should be running, are often overlooked in manufacturing.
According to John Petkovsek, the company's Environmental, Health and Safety Director, it takes a lot of planning to map out more energy efficient production lines. But Lincoln continues to alter its methods, redesigning production lines so that the flow of materials is more organized in order to limit the energy used to handle and transport products.

?Making our process more energy efficient continues to be a learning process,? says Petkovsek. ?We?re always challenging ourselves to come up with new ideas and methods.?

This manufacturer has been ISO 14001 certified since 2004 and strides to operate in an environmentally sustainable manner, from internal processes through product performance. Not only are the manufacturing facilities and corporate offices cutting back on unnecessary use of energy, but the firm is also committed to bringing more energy efficient options to their customers through equipment initiatives and heightening customer awareness of these new product offerings.

The new Green Initiative Awareness Program was formally launched with a new ?Green Initiative? logo that clearly states a product?s environmentally preferential advantage and help customers easily identify products created with energy efficiency in mind. A website, www.lincolnelectric.com/green, was developed that further explains the initiatives.

Initially, the company focused its efforts to provide efficient product offerings on two equipment initiatives, its inverter technology and diesel-engine driven welders. Beginning in 2011, the U.S. Environmental Protection Agency (EPA) will require diesel engine suppliers to reduce exhaust emissions on new engines that are manufactured for use in the U.S. for off-road products. Any diesel engine ? including diesel engine-driven welders ? must meet either the EPA Tier 3 or EPA Tier 4i standards.

Since the fall of 2008, this manufacturer has upgraded its entire line of diesel-engine driven welders to comply with these new standards, two years earlier than required by the EPA. Included in these products are an engine drive that is ideal for cross-country pipeline welding and another with consistent DC generator welding output. Both units are available with EPA Tier 4i compliance.

EPA Tier 4i is an interim standard with lower emission levels than those required to meet Tier 3, but it is not as low as Tier 4 Final. Tier 4i engines can be manufactured for an additional year before Tier 4 final goes into effect. Lincoln?s engine suppliers already meet the Tier 4i standard, so these engines will be in use for the next five years.

REDUCING CUSTOMER CONSUMPTION
Customers who have integrated portable, lightweight inverter-based welding power sources in their stick, TIG and multi-process welders have already embarked upon energy savings simply by making the switch to this technology in their shops.

Machines featuring inverter technology are smaller, with a more compact design and lighter weight than traditional transformer power sources at a comparable price. They save customers around 10 percent in annual costs.

These inverter-based power sources operate at higher frequencies than traditional power sources, meaning they require less output inductance for smooth operation. Higher frequencies allow for smaller, more efficient magnetic components that require less electrical power and reduce overall energy use.

?The inverter is an attractive option,? says Bruce Chantry, equipment portfolio manager. ?Because of its efficiency, this power source can provide substantial savings in utility costs, as well as offer greater control of arc variables and arc fine tuning for the best possible weld.?

The move toward increased energy efficiency and environmental responsibility in the welding industry is ever evolving. While the concept of ?going green? used to be thought of as a fad, it?s evident that it is a true necessity of reality as society and governmental regulations demand a closer look at sustainable manufacturing processes and the resulting products.

?We understand no environmental journey has a true endpoint,? Petkovsek says. ?To this end, we continue to seek out new ways in which to improve upon the initiatives we already have in place. We are poised to take such measures to the next level, continuing to exceed expectations and requirements of our employees, our customers and the society in which we operate.?

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The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, OH 44117, Phone: 216.481.8100, Fax: 216.486.1751, www.lincolnelectric.com.