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As you probably know, California has the most stringent pollution standards in the country. If you examine the facts you will find that most other mills are not required, nor do they live up to these standards. Most of the green you do see are Johnny Come Lately Mills playing the green card in states that are lax on industry pollution and cost less to manufacture in. They claim green on the basis of a small item or material put into their product that qualifies them to claim green. Lately they have been improving their record on the enviorment.
The facts are as follows :
Royalty Carpet Mills has been living green for many many years.
One Earth, One Chance: Royalty Carpet Mills and the Environment
At Royalty Carpet Mills (Pacific Crest Mills) we deeply respect the beauty and inspiration of nature; in fact the company was named after the Pacific Crest Trail in the Sierra Nevada mountains at its founding in 1978. In that spirit we accept that it is our responsibility and obligation to reduce the impact of our processes on the environment and the demand for non-renewable resources.
Resource Efficiency
Reclaimed Water In 1996 PacifiCrest Mills became one of the first businesses in Irvine to connect to the city's then newly-created reclaimed water distribution system. By using reclaimed water we save millions of gallons of potable water per year. For this effort, we received the "1997 Water Winner Award" from the Irvine Ranch Water District.
Energy Co-Generation A move that helped pioneer a new technology in energy efficiency was the installation of two co-generation engines in 1993 for Royalty Carpet Mills. From one fuel, natural gas, we create steam for turbines that generate electricity for our manufacturing facilities. The steam is then re-used to heat water for our dyeing equipment. Thus, one fuel source yields two types of energy-electrical and thermal. By generating our own electricity at Royalty Carpet Mills we reduce demand on the local public utility company and the regional power grid. Another key benefit is that natural gas creates as little as one-twentieth the emissions of the coal or oil traditionally used to generate the electricity alone.
Reclaiming Nylon Nylon sheared from the surface pile of carpet as it goes through the finishing process is aggressively vacuumed as it is sheared. The sheared nylon is collected, bagged, and sold to be melted down and used in the manufacturing of automotive parts. This reduces the demand for virgin raw materials made from petroleum, one of the world's most critical non-renewable resources.
Heat Recycling Heat recycling technology also came to us in the multimillion-dollar modernization of our finishing line, which became operational iRoyalty Carpet Mills January 1997. The new system dramatically reduces energy use and eliminates tons of air emissions per year.
Low Impact Manufacturing Practices at Royalty Carpet Mills
Air Quality PacifiCrest Mills and its parent company, Royalty Carpet Mills Inc., historically have been proactive in implementing environmental safeguards and in surpassing all environment compliance regulations. In fact, we were recently name a Clean Air Partner with the South Coast Air Quality Management District, among the strictest environmental regulatory agencies in the USA, for exceeding five years ahead of schedule the 2004 target levels for NO2(nitrous oxide) emissions.
Reclaimed Water Re-Use During the dyeing process, the dyestuffs are almost completely absorbed by the carpet and the post-dyeing water is virtually clear. We further clean it in a de-fuzzing process to remove nylon fiber. It's then returned to the Water District's reclaimed water distribution system for further industrial use. Thus, the reclaimed water is used again and again for non-consumer purposes in a closed-loop environment.
Indoor Air Quality Protection All PacifiCrest products exceed the "Green label" specifications for low emissions of volatile compounds (VOCs) established by the Carpet and Rug Institute, by using the lowest-VOC materials available in the backing process.
Re-Use, Recycling, Reclamation Standard procedure at Royalty Carpet Mills,
Reclamation of Hard Waste from Manufacturing Hard waste from manufacturing, primarily factory-trimmed pieces of finished carpet which includes nylon fiber, the polypropylene backings and the latex binder, has recently found a new life. In a newly developed process the waste is heated and pulverized to a grainy consistency, then used as a binder in asphalt paving projects. Other technologies are turning this scrap into mixed-plastic materials for under-hood automotive applications or as a substitute for gypsum drywall. Re-use of Packaging Materials. The hard cardboard cones used to hold yarn for tufting are all sent back to our yarn processing plant to be reused. Carpet cores are used over and over as carpet is rolled up and unrolled during various manufacturing processes. Cardboard boxes used in yarn transport are broken down and sent back to the Royalty Carpet Mills yarn plant for repeat use.
Recycling and Responsibility in Our Plants and Offices
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Scrap metal from repair or retrofitting of equipment is sent to a metal recycler.
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Water for pump seal cooling is recirculated in a closed-cycle system.
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Shrink-wrap used in bundling yarn shipments is reprocessed in much the same way supermarket bags are turned into new packaging.
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Paper from office use is collected separately from other waste and is recycled.
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Bins in lunch rooms and break areas have been set aside to collect aluminum soda cans for recycling.
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Dedicated preferred parking spots and other employee incentives have been established to encourage carpooling to reduce traffic and pollution.
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Plant hours have been arranged so that shift changes and the resulting impact on local traffic occur at non-peak hours.
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We use electric lift trucks in the manufacturing and shipping areas.
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All offices and plants are smoke-free zones.
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We use super granulated dyestuffs to eliminate dusting.
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Complete spill recovery procedures are in effect.
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PacifiCrest provides used cardboard drums to local chemical suppliers for re-use or uses returnable totes and drums.
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We return all used motor and machine oil for safe disposal.
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We are an active participating member of the CRI West Coast Technical Committee, promoting and pushing for reform on many environmental issues including use of recycled water, Title V-Clean Air Act, carpet recycling, scrim waste disposal and indoor air quality.
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PacifiCrest and Royalty Carpet Mills work hand-in-hand with suppliers to educate them on California's environmental initiatives.
Copyright © 2008 by PacifiCrest Mills, Inc.