EPA Announces Most Energy-Efficient Manufacturing Plants in Alabama

Today, the U.S. Environmental Protection Agency (EPA) is announcing that three U.S. manufacturing plants earned the agency’s 2022 ENERGY STAR certification in Alabama, a designation reserved for manufacturing plants in the top 25% of energy efficiency in their sector. Nationwide, 86 U.S. manufacturing plants earned the agency’s ENERGY STAR certification in 2022. Together, these plants saved over 105 trillion British thermal units (Btus) of energy and prevented more than 6 million metric tons of carbon dioxide emissions, equivalent to the emissions from the electricity use of more than 1.1 million American homes.

“Industrial leadership in energy efficiency is critical to achieving our nation’s climate goals,” said EPA Administrator Michael S. Regan. “The savings from ENERGY STAR certified plants demonstrate how energy efficiency is both helping our manufacturing sector reduce costs and propelling America’s transition to a clean energy future.”

“We congratulate our Region 4 manufacturing plants that earned their 2022 ENERGY STAR certification,” said EPA Region 4 Administrator Daniel Blackman. “Their innovation and leadership enhance America’s economic competitiveness, reducing costly energy waste improves public health while protecting the environment.”

The industrial sector accounts for 30% of U.S. greenhouse emissions, primarily from energy use in manufacturing plants. ENERGY STAR certified plants have reduced their energy consumption through a variety of energy efficiency projects and management practices. For example:

Primient’s Loudon, Tenn., and Lafayette, Ind., wet corn mills reduced their CO2e emissions by installing and optimizing combined heat and power systems.
Nissan North America’s Canton, Miss., vehicle assembly plant formed a team to track compressed air leaks, leading to an annual reduction of approximately 1,700 cubic feet per minute of compressed air. The company’s Decherd, Tenn., powertrain assembly plant created scorecards to benchmark the shutdown performance of facilities, assigned countermeasures to shops not meeting targets, and provided recognition to top performers.
Cemex’s Miami, Fla., cement plant increased its energy performance in 2022 by modifying a finish mill, optimizing the ball charge on the largest mill, and identifying and correcting potential energy losses while also increasing the production of Portland Limestone (Type IL) cement.
Titan America’s Troutville, Va., and Medley, Fla., cement plants have completely converted production to Portland Limestone (Type IL) cement, with up to 15% less embodied carbon than standard Portland Cement. Since 2015 the two plants also have achieved a 12% reduction in electricity use and an 18% reduction in CO2, respectively, from improved energy management.

Manufacturing plants use EPA’s ENERGY STAR energy performance indicators or, in the case of petroleum refineries, the Solomon Associates Energy Intensity Index scoring system to assess their energy performance. Plants that score a 75 out of 100 or higher—indicating that they are more energy efficient than 75% of similar facilities nationwide—are eligible to earn ENERGY STAR certification. ENERGY STAR certification is available for 20 manufacturing sectors, from cement and steel to glass and commercial bakeries.

2022 ENERGY STAR certified manufacturing plants in Region 4:

Alabama:

Georgia-Pacific, Brewton (integrated paper mill)

Honda Development & Manufacturing of America, Lincoln (automobile engine)

Tuscaloosa Organic Baking Co (commercial bread and roll baking)

Florida:

CEMEX USA, Miami (cement manufacturing)

Titan America, Medley (cement manufacturing)

Georgia:

Honda Development & Manufacturing of America, Tallapoosa (automobile transmission)

Kentucky:

Bimbo Bakeries USA, Inc., London (commercial bread and roll baking)