DC Velocity - April 2015

str at e g ic i ns i g ht FA CI LI TY P LAN NING AND D E S IGN

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lated wall panels. If the facility includes automated storage areas, don’t cool or heat these sections unless the product requires it. In addition, consider painting the facility’s roof—white in hot climates and black in colder climates— which will either reflect or trap heat from the sun.

To keep heated or cooled air from escaping through loading dock doors, install dock seals. Murphy Warehouse Co. takes the added step of placing insulated blankets on the steel dock plates when not in use in order to reduce air leaks. As a result, the company’s docks are now 10 degrees warmer during frigid Minnesota winters. The use of large circulating fans also helps even out temperatures within buildings—pushing warm air down in the winter and reducing reliance on air conditioning in the summer.

b Facility lighting: The use of energy-efficient lighting can produce big savings over time. Costs for technologies such as LED have dropped significantly in recent years, allowing companies to recoup their investments more quickly. For instance, Richard Murphy expects a payback on the LED fixtures installed in several of his warehouses in just over four years. As an added bonus, he won’t have to touch the bulbs for 17 more years, saving many man hours usually spent replacing lamps. An alternative to LED is fluorescent lighting such as T- 5. Compared with LED, fluorescent lighting offers a more favorable ROI (less than three years) but it requires bulb replacement every three years. Adding motion sensors to turn off lights when no one is present also saves a great deal of energy.

b Energy/power production: Some facilities have taken to creating their own power. For instance, gas wells on site may provide heat. For his part, Murphy installed solar panels on his facilities to collect additional power and to feed batteries that are used for emergency lighting. It’s important to bear in mind that solar and wind projects currently have a very long return on investment. Most of the facilities that have gone down this path have relied on government incentives to help fund the installation and offset the lengthy payback period.

b Material handling equipment: Choose equipment with an eye toward energy efficiency. For instance, MDR (motor driven roller) conveyors significantly reduce energy consumption and can power down when there’s no product present to convey. Efficient battery management and fast charging can help reduce a lift truck fleet’s power consumption. Alternative fuels for lift trucks, such as hydrogen, are also gaining ground, albeit slowly. Designing the facility to lessen long lift truck runs can reduce energy consumption as well as wear and tear on the vehicles.

Whether you opt to take the LEED certification route or not, going green can bring big payoffs. All of these efforts to reduce waste, save energy, and generally adopt sustainable practices can make a huge impact on your business and on the planet. Richard Murphy sums up his mission this way: “Are we changing the world with what we are doing? We are trying.”

b Landscaping: When choosing plantings for the building site, opt for natural grasses that don’t require regular watering. Natural grasses reduce storm-water runoff and require significantly less maintenance than traditional lawns (think less mowing and less mower exhaust). Murphy, who began his career as a landscape architect, says that “cut” grass is

7. 3 times more expensive than native grasses. He has saved almost $1 million on two facilities in two years using native grasses and flowering plants. Adding trees also helps limit water runoff, and the trees provide a more attractive visual buffer for neighbors who would otherwise stare at dock doors.

b Employee well being: Such amenities as an onsite gym, shower facilities, and walking trails on the property will go a long way toward promoting healthy lifestyles. Similarly, providing bicycle racks and parking spaces for hybrid and electric vehicles helps underline a company’s commitment to employee fitness and air quality.

b Air quality/water conservation: To minimize indoor air pollution, choose nontoxic paints and floor coverings. Promote water conservation by using waterless urinals and low-flush toilets. Adopt cleaning practices that limit the use of water, and choose cleaning solvents that are environmentally friendly.