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WINCHESTER SPRING – Winchester, KY

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Winchester Spring obtained Eco Initiative registration on July 31, 2012. As a result of their sustainability work, they were awarded the 2012 Environmental Excellence Award by the Kentucky Department for Environmental Protection (KDEP). In 2015, the facility was awarded the Environmental Pacesetter Award by the KDEP.

Initially, the facility implemented small changes, such as reducing Styrofoam cup usage, saving coffee grounds for compost, and setting up color-coded containers to separate recyclables. The facility then moved on to bigger projects, such as:

  • Reviewing and improving air compressor use to increase efficiency, reducing energy usage and operating costs.
  • Reducing landfill disposal by 60% by recycling cardboard, paper, steel, plastic, aluminum cans, pallets, and oil pads.
  • Working with the local electric company to improve energy use efficiency. The project has a projected savings of $20,000 per year.
  • Implementing a paperless system. From 2009 to 2010, paper usage was reduced by 44% and reduced another 28% by 2011.
  • Joining the KY Green Fleets Project, which monitors tractor/trailer energy usage and gives advice on best practices.
  • Implementing a program to rebuild parts, reducing the purchase of new parts and the disposal of used parts. Through the implementation of this program, the facility has reduced new parts purchased by 25%.
  • Reducing water consumption by installing new water fixtures and placing filled water bottles in all toilet tanks. Water usage has decreased from 83,000 gallons per month in 2010 to 82,000 gallons per month in 2012.
  • Replacing 100% of the oil lubricant used in the wire forming process with a dry lubricant. In addition, oil containment/recycling systems were installed on Spühl innerspring equipment to capture machine oil leaks. This reduced machine oil usage by 50%.
  • Switching from propane forklifts to electric forklifts. This reduces air emissions and propane usage.
  • Forming a team named “Garbage Pail Kids” to achieve a scrap metal rate of 4% in 2006. By April 2012, the facility’s scrap rate had dropped to 0.99% through various projects and changes made at the facility.
  • Installing motion sensor lighting to reduce energy use in areas with no employees and installing energy-efficient lighting throughout the facility.
  • As part of the Eco Initiative Social Responsibility requirement, facility employees are also involved in environmental projects outside the work place. Recently, they participated in the Clark County Community Clean-Up by picking up trash in the community.

    In 2014, Winchester Spring set new goals to obtain for the year. The facility aimed to reduce new parts purchases by 25% by rebuilding parts (reusing). They set out to identify opportunities for energy efficiency by assessing air compressor efficiency, and aimed to set up a process for repairing ComfortCore® pallets and improving return of pallets from customers so they could recycle 90% of non-usable pallets by finding a vendor for them. The results of these three big projects as of August 2014 were:

  • The facility installed a 300 HP compressor and moved its 150 HP compressor.
    • Projected savings of $25,000 for both buildings.
    • $18,000 savings to date at New Street.
  • Parts rebuilding project.
    • Project savings YTD = $385,866.
  • Pallet return project.
    • Project savings YTD = $18,550.
    • Vendor is taking pallets that need to be recycled at no cost for Leggett.

    The current goals that have been established for 2015 are as follows:

    • Install LED lighting to all Spühl equipment.
    • Implement a recycling program for Jowat glue bags. Glue bags are cleaned and reused. Using 275 polypropylene (PP) glue bags a year, the facility projects avoiding 20 square feet of PP from entering our waste-to-landfill stream. That’s a total of 1650 pounds!
    • Phase II includes recycling mop heads at Ecton Road (already implemented at New Street), preventing 130 mop heads from going to landfill.

    In 2015, Br 02 partnered with the Clark County Lions Club ink cartridge recycling/fundraising drive. Proceeds from recycled ink cartridges go to the Lions Camp Crescendo, a non-profit organization dedicated to the enhancement of the quality of life for youths, especially those with disabilities.