Kodak (Australasia) Pty Ltd

Use of Energy-Efficient Tri-Prosphor Lamps: Kodak (Australasia)

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Courtesy of Kodak (Australasia) Pty Ltd

Kodak (Australasia) Pty Ltd has successfully implemented a cleaner production initiative in a building, which is used to fabricate plastic and metal products. The initiative raised illumination levels by 128 percent while lowering electricity use by 30 percent. The changes involved cost $21,350, had a direct payback period of 3.8 years, and substantially improved the working environment.

Background

Kodak (Australasia) Pty Ltd manufactures and distributes photographic and multi-media products and services to markets throughout Australia, Asia and the Pacific.

The wholly-owned subsidiary of Eastman Kodak Company in the US, the Australian operation has headquarters in Melbourne and employs over 2,400 people in imaging, information technology and health services. One of just eight Kodak manufacturing plants worldwide, the company is Australiaís sole producer of film and paper for the photographic industry.

Almost 80 percent of production is exported each year, primarily to Asian and Pacific rim countries. During the decade of the 1990s, Kodak will export $3 billion worth of Australian-made product to South East Asia, making it one of the countryís top exporters of high-technology goods.

Kodak Australasia is a leading proponent of Total Quality Management and in 1992, won the nationís inaugural Quality Prize in recognition of its world-class management and outstanding business results.

The Process

Kodak Australasia fabricates plastic and metal products in a building which has a three metre high ceiling, was originally lit by fluorescents, and in which lighting levels were half those required to properly carry out the fabrications. The old light fittings were causing maintenance problems with leaking capacitors and a high failure rate of control gear.

Cleaner Production Initiative

Kodak was able to transform lighting conditions in the building by implementing recommendations made by consultants aimed at rationalising and refurbishing existing fittings.

To achieve better lighting at lower cost, Kodak replaced the existing control gear with low-loss ballasts and new capacitors, and with electronic ballasts in many of the fittings. Reflectors were cleaned and replaced. Tri-phosphor lamps were used to replace fluorescents.

Because of its concern about the environmental impact of disposing of over 800 lamps, Kodak collected all the old fluorescent lamps and disposed of them in a lamp recycling machine, which recovers glass, metal and mercury for reuse.

Advantages of the Process

The new tri-phosphor lamps put out more light, produce better colour and last longer than conventional fluorescents. By keeping the 400 existing fittings, costs were reduced.

As a result of the changes, illumination levels were raised by 128 percent, and electricity use was lowered 30 percent (equivalent to a reduction of CO2 emissions of 29.3 tonnes). The changes involved cost $21,350, had a direct payback period of 3.8 years, and substantially improved the working environment.

The cost savings more than justified the lighting upgrade. Due to the success of the project, Kodak immediately made similar changes to the building's basement warehouse.

Cleaner Production Incentive

Poor lighting levels were hindering fabrication operations and old light fittings were causing serious maintenance problems.

Barriers

No barriers were experienced in implementing the recommendations made by the consultants.

Reference

Case study coordinated by the Environment Management Association of Australia (EMIAA), May 1998.

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