1999

1999 Award Winners

• Enron Wind Corp. and HDR Engineering, Inc.
• Genmar Holdings, Inc.
• The WATER Foundation
• Western Lake Superior Sanitary District
• Wildrose Farm
• Honorable Mention: Marvin Windows and Doors
  

In 1998, Lake Benton Power Partners, LLC, completed development of Lake Benton I, the world’s largest single wind power project. The 107,250-kilowatt installation of Lake Benton I is designed to provide non-polluting renewable energy for distribution by Northern States Power Company.

			“This facility established the benchmark standard for large wind power developments on the Great Plains. Enron and HDR have successfully employed the Lake Benton I Model on three other utility scale wind power projects in Iowa and Minnesota.” Robert Gates President of Enron Wind Development Corp.

The 21-square-mile wind power facility was built with the goal of harvesting wind with little impact on farmland and the existing environment. Each of the 143 wind turbine units is mounted on a steel tower 50 meters high. The propellers that turn in the wind to produce electricity are 46 to 50 meters in diameter. Lake Benton I is the first large wind energy project to be constructed with the newly developed Zond Z-750 turbines. Each unit is a totally self-contained power plant with the ability to operate independently of the other 142 generating units and has a 750-kilowatt capacity. Lake Benton I provides enough non-polluting electricity to serve 43,000 homes. These state-of-the-art generating units exceeded the installed power capacity objective by more than seven percent.

In addition to being the largest renewable energy facility in Minnesota, Lake Benton I is also a leader in pollution prevention. By displacing fossil fuel in electrical generation, this project annually offsets 347 million pounds of carbon dioxide, the leading greenhouse gas. The displacement of fossil fuel also reduces emissions of sulfur dioxide, nitrogen oxides and mercury. Throughout the entire development process, Lake Benton Power Partners, a subsidiary of Enron Wind Corp., has remained committed to the protection of existing environmental resources while developing a sustainable non-polluting energy resource.

According to a spokesperson for the U.S. Department of Energy, Lake Benton I will have the air quality impact of taking 50,000 cars off the road. This world-class renewable energy facility will supply wind generated electricity for the next 30 years. The city of Lake Benton has enthusiastically embraced its new distinction as “The Wind Power Capital of Minnesota.” The Lake Benton I project will continue to provide significant local tax revenues and be a source of community pride well into the next century.

Genmar Holdings, Inc.

The objective of this project was to develop a technologically advanced, closed molding process for the manufacturing of fiberglass boats in a high-production setting that would result in reductions of air emissions and solid waste. Through input of capital, boat-building expertise, and experiences gained through the testing of various fiberglass closed molding technologies since 1990, Genmar developed VEC™ advanced engineered composite process for boats.

		“Genmar's goal is to be the leader in the marine industry in 21st century technology and we've invested our time and money into VEC™ because we believe it's a manufacturing process that will change the way our industry has built fiberglass boats for the past 30 years. In fact, we believe this process will become the new standard used by boat builders worldwide.” Irwin Jacobs Chairman of Genmar Holdings, Inc.

The industry standard is the “open-faced” molding system, which is extremely labor-intensive and generates waste and emissions of styrene. With the VEC™ process, the fiberglass boat parts are manufactured in a closed-mold environment, which will result in a 77-percent decrease in styrene emissions compared to open molding, and also a significant reduction of solid waste. At the planned production rate of 6,800 boats per year, manufacturing of the decks and hulls with VEC™ would decrease styrene emissions by approximately 30 tons per year once the project is in full operation.

Employees now work in a cleaner work environment. With the VEC™ process, there are lower levels of airborne styrene than in open molding areas, and there is no resin or fiberglass on the walls and floors due to overspray. It is Genmar’s goal to use the VEC™ process to manufacture the hulls and decks for all of the smaller boat models (16 to 22 feet long) produced at the Larson/Glastron plant. Genmar plans to market this process to fiberglass boat plants nationally and believes that this process will eventually become the industry standard.

The WATER Foundation

The W.A.T.E.R. Foundation’s mission is to teach conservation of natural resources through practical products and programs. The Eco-Domes building houses the W.A.T.E.R. Foundation’s offices, but was designed as a residence.

			“Anyone who wishes to build or install conservation technologies in their buildings can do so with a few hours of extra effort. The paybacks are many, but what I like most is to watch how wonderfully all the nature-powered systems work every day.” David Winkelman President of the W.A.T.E.R. Foundation

The Eco-Domes building was designed to have zero impact on the environment. Constructed using the latest technologies to conserve energy, materials and water, the Eco-Domes burn no fuel, produce only one cubic foot of compost per year and have only minimal water use because of the composting toilets. The Eco-Domes building is a showcase for environmental options in building, heating, lighting and design. Multiple aspects of the building are designed to provide economic efficiency as well. Solar and wind power create 75 percent of the electricity used by the utilities and appliances in the building. The investment in wind power should pay for itself in five years, after which the electricity is virtually free except for maintenance.

• The geodesic dome uses 33 percent less material to enclose the same floor area than square buildings.
• In every aspect of the building, conservation options to reduce energy use, reduce waste, recycle water, and use alternative forms of energy were incorporated.
• The headquarters building contains approximately 10,000 square feet and was built at a cost of approximately $48 per square foot, compared to standard building costs which range from $60 to $125 per square foot.
• Wood floors in the dome are made with the lowest grade of lumber, and the paints, sealers, carpets, and tiles used contain virtually no volatile organic compounds (VOCs).
• All toilets in the building are composting toilets, and require no flushing or septic system. The toilets generate zero pollution and turn the waste into useful fertilizer which can be safely spread in the flower gardens or forest.
• The domes use fluorescent lighting, which saves energy.
• The insulation is made of recycled newspapers and recycled glass, and the building is heated and cooled using heat pump technology which uses ground water to gather geothermal energy underground.
  

The W.A.T.E.R. Foundation uses its buildings to educate and encourage interest in building zero impact buildings by providing public tours every third Friday of the month. A visit to the Eco-Domes will demonstrate ways to better harmonize with nature, conserve natural resources and save money, all while portraying an “up-north” charm. The W.A.T.E.R. Foundation was also been chosen to receive a 1999 Minnesota Waste Wise award.

Western Lake Superior Sanitary District (WLSSD)

Western Lake Superior Sanitary District (WLSSD) is the largest wastewater treatment facility discharging into the Lake Superior watershed and supports a zero discharge policy of toxins within the Lake Superior basin. The plan for this project was to develop a strategy to reduce the discharge of mercury by using pollution prevention techniques that would work right away and in the future.

			“WLSSD's source reduction program has shown that significant, long-term reduction in mercury loading can occur using practical, proactive pollution prevention approaches. The most important lesson is that this approach can be adopted or modified for other organizations.” Kurt N.W. Soderberg Executive Director of WLSSD

One of the first internal changes made by WLSSD was a modification of the way mercury-containing scrubber water from the incinerator was handled. Scrubber water from the incinerator was pretreated and contained within a closed-loop system to reduce mercury loading to the treatment plant. Another internal improvement in the solid waste processing system resulted in production of a cleaner fuel for incinerating sludge in the wastewater treatment process. A higher percentage of ferrous metals were removed from the solid waste processing stream and staff training improved other on-line removal of problem materials as well.

WLSSD’s pollution prevention program has resulted in significant reductions in the amount of mercury released to the environment from its facilities.

• Between 1990 and 1996, WLSSD reduced mercury in dry sludge from its treatment operations from 4.5 parts per million (ppm) to 1.15 ppm.
• Mercury concentrations in the effluent discharged to the St. Louis River also went down in that time period, from 0.58 parts per billion (ppb) to 0.015 ppb.
• WLSSD continues to see mercury reductions, with the average dry sludge concentration for 1998 at 0.87 ppm and the average effluent concentration at 0.012 ppb.

WLSSD developed a public education program called MercAlert to increase public awareness about mercury in the environment and promote alternatives to mercury-containing products and the proper disposal of mercury-bearing wastes. The MercAlert Program has been a model for similar educational campaigns in other states and is credited with helping WLSSD achieve reductions in mercury emissions. This program began with public education and building public awareness that led to partnerships within the community which identified and reduced mercury contributions from schools, hospitals, dentists and industry. WLSSD has shared its experience with others in the Blueprint for Mercury Elimination (March 1997) and serves as a mentor for other communities working on mercury reduction issues. WLSSD also took a leadership role in developing the Lake Superior Partnership in 1994. This brought industries and regulators together and helped businesses get into compliance with environmental regulations and to work toward more pollution prevention in their processes. WLSSD was also been selected as a recipient of 1999 Minnesota Waste Wise and MnGREAT! awards.

Wildrose Farm

The objective of Wildrose Farm is to produce and sell quality, environmentally sound products in a safe and clean setting, and recycle all of the manufacturing by-products. In its fourth year of operation, this family-run business is involved in custom-sewing, woodworking and organic gardening. The company’s main concerns are the use of organic cotton, grown without agricultural chemicals, for a line of clothing manufactured on-site and sold nation-wide, and the sustainable harvesting and planting of timber for buildings and projects.

		“We consider this venture to be a good beginning. Each project inspires new ideas, which involve more people, working to produce pro-environmental alternatives and improving the quality of life.” Charles and Karen Knierim Co-founders of Wildrose Farm

Wildrose Farm uses 100 percent of its by-product fabric scrap; the larger pieces are woven into rugs, and the smaller pieces are made into paper. The scraps from an 800-garment order last year were used to make 30 rugs. The rugs are heirloom quality destined for long-term use. Paper made from organic cotton is archival quality, and no toxic waste is generated from its manufacture.

The sewing studio is heated with an in-floor hot water system and shares a furnace with the farm house and office, resulting in a 75-percent savings in fuel. Non-toxic, water-based inks are used to screen print designs on the clothing. Special employee benefits include “Make Your Own Clothing Days” with free fabric. Employees also receive discounts on organic health care items and environmentally safe cleaning products sold in the Pequot Lakes store called Wildrose Farm Organics. Wildrose Farm also reaches out to the community in a program that uses recycled metal and glass to make buttons and furniture hardware.

A recycling page will be added to the Wildrose Farm Web site, which will provide innovative uses for recyclable materials, links to related sites, and information on purchasing recycled products. Wildrose Farm is taking responsibility for all resources brought into their operation. Wildrose Farm’s goal is to use the most environmentally-sound resources available, manufacture them into quality products in a safe and clean setting, and discharge no toxins from the process. This has been fulfilled by the constant dedication this family has for their growing business.

Honorable Mention:
Marvin Windows and Doors

Warroad-based Marvin Windows and Doors has developed several projects that demonstrate their corporate responsibility and strong commitment to pollution prevention and environmental protection. A 1996 Governor’s Award recipient, Marvin continues to build upon their commitment to the environment through the implementation of several new programs.

One substantial change was Marvin’s decision to replace their solvent-based spray painting option for assembled wood windows and doors. They now use pre-painted aluminum clad featuring a low-maintenance finish applied by Marvin’s extruded aluminum clad supplier. This has several benefits:

• The decision to use this system exclusively led to the elimination of all volatile organic compound (VOC) emissions from this Marvin operation.
• The supplier’s aluminum clad painting system is more efficient than spray painting wood. It consists of a vertical, electrostatic turbo disk system that adds a positive charge to the paint. The negatively charged aluminum extrusions pass through the totally enclosed painting system which results in maximized paint coverage and transfer efficiency.
• Using this supplier's system has reduced the release and exposure of toxic chemicals at Marvin's facility by a considerable amount. At a typical manufacturing output, Marvin sees a reduction in VOC emissions of approximately 50 tons per year. It also results in painting cost savings to Marvin of over $700,000 per year. This program is a joint effort in which the environmental benefits are maximized by the partnership.

In addition to the elimination of solvent painting operations, other practices at Marvin have greatly reduced the use of chemicals.

• The Product Analysis Request form used to request new products has been put into place to carefully examine and research products or samples prior to their implementation in the facility. Products are evaluated to ensure all safety and environmental requirements are met. The process is effective in either preventing chemicals from entering the facility or restricting their use.
• Changes in facility operations and the decline in chemical use have greatly reduced the amount of hazardous waste generated from the Marvin facility. Between 1995 and 1998, there has been a 93-percent reduction in hazardous waste.
• The implementation of a reusable packaging system for glass resulted in the elimination of 143,000 pounds of packaging waste in 1998.
• Marvin has also made air compressor efficiency improvements, reducing energy use by 166,000 kilowatt hours per year.

As a leader in the wood window and door industry, Marvin recognizes its responsibility to environmental protection. Marvin Windows and Doors was also chosen for a 1999 Minnesota Waste Wise award.

Updated September 1999