In September last year, some 300 workers died in a garment factory fire in Pakistan, many because they were trapped behind locked emergency exits. Six months later, another 1,100 seamstresses were crushed to death when an eight-storey building collapsed in Bangladesh, despite warnings it was unsafe.

As the multi-trillion-dollar textile industry struggled to respond to these tragedies, the much smaller global toy industry was able to call on a resource no other consumer product industry can match.

In short order, big toy brands and retail members of the International Council of Toy Industries (ICTI) were able to tap into a one-of-a-kind database they have built over the past decade known as the ICTI CARE (Caring, Awareness, Responsible, Ethical) Process (ICP).

The trove of data, which includes wage rates, hours worked, worker age and 200 or so other metrics at thousands of toy factories, allowed big toy buyers to rapidly identify manufacturers located in the areas affected by the recent labour disasters for focused follow-up. Within weeks, industry executives started to develop and roll out tougher rules to all of the factories in the ICP network, guiding inspectors to enforce stricter requirements for fire escapes and building integrity.

The quick response was made possible by a combination of ICP’s carefully cultivated industry collaboration together with a recent decision to port its unique database onto a web-based platform provided by Enablon, a supply-chain software service provider founded in 2000.

“Not long ago, this sort of information was considered proprietary. A single factory might have two dozen clients, but they didn’t want to talk to one another, for fear of competitive disclosure” says Philippe Tesler, co-founder and CEO of Enablon North America.

A combination of factors has rewritten these habits. There’s a growing recognition that risks can be lowered and costs minimized through collaboration. “Reporting has gone from a defensive response to a more proactive process,” says Tesler.

Back in 2002, the toy industry was facing a series of relatively small-scale labour mishaps at overseas factories. “Pressure was building from retailers, from consumers, NGOs [non-governmental organizations] and investors to boost regulation,” recalls Christian Ewert, president and CEO of the ICTI CARE Foundation, which oversees the supply chain program.

Instead, the industry group pushed for self-regulation and established the ICP, a framework in which toymakers would share and compare information towards the end of “ensuring safe and humane workplace environments for toy factory workers worldwide,” says Ewert.

Notably, the ICP was established as a standalone not-for-profit, overseen by a board that includes NGO and civil-sector experts, and on which active toy industry executives are in a minority.

Streamlining inspection efforts has been a central priority from the beginning. When Ewert started in the toy industry in the 1990s, he worked with a manufacturer that faced 64 audits per year, each asking for similar information. “I’d much rather have seen those auditors inspecting 64 different factories, rather than the same factory 64 times,” he says.

The move to Enablon’s platform has helped transform this process from a cumbersome paper chase into a more scalable, easier to use and fast-evolving technology. On a factory floor in China, auditors and factories can input data wirelessly. On the other side of the planet, ICP members can log in and tweak standards on the fly, and do deep data analysis across the factories they are working with.

Today, the system tracks data on roughly 2,500 factories that employ some one million workers. Most are based in China, home to a vast majority of the world’s toymakers. Just 1,600 factories are currently certified as meeting ICP’s criteria. New factories join each year, but year to year about 13 per cent lose their approved status.

The most frequent causes for such a loss? A lack of transparency about whether workers are paid correctly or companies are demanding too many hours of work, says Ewert. Picking up such malpractice early can nip bigger problems in the bud, lowering the risk to corporate reputation.

“Companies don’t want to be named and shamed,” says David Metcalfe, CEO of Verdantix, an independent analyst firm focused on energy, environment and sustainability issues.

Over time, Metcalfe adds, the best employee health and safety plans can evolve to do more than protect workers. They can also proactively improve supply chain operations by identifying potential trouble spots, focusing corrective responses and avoiding the cost and hassle of switching factories following a crisis.

ICP, for example, goes beyond simply tracking auditors’ reports. It reaches out to workers directly. Factories are required to post a hotline to which workers can anonymously phone in problems. The organization receives up to 350 such calls per month. When the software detects a spike in calls from a given factory, ICTI CARE can increase its training efforts with both staff and management, before a crisis breaks.

And if early action doesn’t work, the threat of being de-certified is a potent motivator, says Ewert. After all, it’s not a single buyer pulling out, but the entire ICP network. Ewert is confident the transparency will continue to grow as technology advances.

“Workers can call us today,” he says. “In time, they’ll be able to send pictures of dangerous conditions too,” as smart phones emerge as another tool to help the industry identify and repair risks before they become tragedies.

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One of Ford’s highest profile eco-efforts can best be seen by looking down on the roof of its River Rouge factory in Dearborn, Michigan. Originally constructed starting in 1917 by Henry Ford, the complex debuted as an industrial pioneer, among the first fully-integrated industrial complexes, where steel mills, glass works and chemical plants were built side by side to speed the flow of raw materials into Ford’s burgeoning Model T plants.

It was there in 2000 that company chairman William Clay “Bill” Ford Jr., the founder’s great-grandson, unveiled another pioneering effort, of a greener hue. He announced plans to build the largest “living” roof ever installed on an industrial building, comprising 10 acres of hearty, green sedum plants.

Green roofs have since become a favourite of building designers. But at the time, Ford’s plan, part of a broader $2-billion site renovation, ran counter to energy-guzzling conventions in the auto biz. U.S. auto sales hit an all-time high that same year, buoyed by record sales of high-margin SUVs and sub-$2 per gallon gas.

Against this backdrop, and even though the roof was estimated to cost about the same as a conventional design, critics carped that Ford was risking money on greenwashing efforts. Yet when the roof was completed in 2002, Bill Ford stood firm. “This is not environmental philanthropy,” he said at the time. “It is sound business.”

Since then, much has changed. Gas prices have nearly doubled, endangering SUVs, and Ford’s green roof gamble continues to pay back by passively lowering the factory’s energy use for cooling, displacing electric illumination with skylights and reducing costs to filter stormwater runoff.

Elsewhere throughout Ford’s global operations, eco-roof features pioneered at River Rouge – such as day-lighting, rain water capture and cool-white materials that reflect sunlight – have become standard design features. Though the most visible, the River Rouge roof wasn’t the only water-focused effort Ford rolled out in 2002. That same year, the company began a long process to radically reduce the amount of water, energy and other resources used in its manufacturing operations.

From the start, metal-cutting machines were a top target. These computer-controlled devices shape hunks of steel and aluminum into precision auto parts, everything from big engine blocks to fine-toothed gears.

The problem? “It can be a messy process,” explains Sue Rokosz, principal environmental engineer at Ford.

Flood machining, as the conventional process is known, uses a steady stream of oil and water to cool cutting tools. This slurps up huge inflows of fresh water, requiring a lot of energy and plumbing infrastructure to keep flowing. And at the back end, it yields a slurry of oil, water and metal particles that are costly to dispose of and difficult to recycle.

As a fix, Ford turned to a process known as near-dry machining, or minimum quantity lubrication (MQL). The process replaces the stream of oily water with micro-spritzes of atomized oil delivered via articulated arms or hollow drill bits to precisely the point of contact where friction and heat build up.

It’s a small improvement that delivers outsized benefits. By making the switch, a typical manufacturing line – capable of machining roughly half a million parts every year – can lower annual water use by about 280,000 gallons and avoid the consumption of more than 28,000 gallons of lubricants.

What’s more, oily wastewater is all but eliminated and the metal shavings are relatively dry and clean, ensuring a higher share is recycled. Line workers benefit too, with drier, safer work areas, says Rokosz.

Though dry-machining systems cost slightly more upfront, their overall lifetime costs pencil out at 17 per cent less than old-style wet machines, according to Ford data.

While the technology has become Ford’s de facto standard, it can be set up only as fast as new manufacturing lines are built or old ones are replaced. So far, it’s been installed in more than a third of Ford’s 28 powertrain plants, with more on deck to make the switch.

Drop by drop, Ford’s water-savings efforts are adding up. According to its sustainability report, Ford has cut water consumption, per vehicle produced, by about half in the past decade. It is on track to cut per-vehicle consumption to around 900 gallons by 2015, compared with over 2,500 gallons in 2000. That’s roughly equivalent to taking 100 fewer five-minutes showers.

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The technology is a relative of the hybrid electric vehicle (HEV) pioneered by Toyota’s Prius, which achieves enviable mileage by recapturing much of the energy lost during braking. Instead of saving that braking energy in batteries, UPS’s new hydraulic hybrid vehicle (HHV) delivers a 35 per cent boost to mileage by storing hydraulic fluids in super strong tanks.

“The hydraulics are the muscle, managed by very sophisticated electronics,” says Mike Britt, director of maintenance and engineering for the company’s international ground fleet.

Hydraulic systems may be new to delivery trucks, but they’re widely used elsewhere. The strength and durability of hydraulic systems have made them a mainstay in countless heavy-duty machines, from fighter planes and garbage trucks to bulldozers and car crushers. But until now, high costs have made it difficult to use hydraulic drives in everyday vehicles.

As part of a long-term government-backed program to study and scale up this technology, UPS began at the end of 2012 to introduce 40 of the advanced Daimler-built hybrids on delivery routes in Atlanta, Georgia, the shipping giant’s hometown, and Baltimore, Maryland.

From the outside, UPS’s hybrids are the same familiar brown boxes-on-wheels that have delivered catalogue orders and holiday gifts for generations. Pop open the hood, however, and you’ll begin to see differences. Inside is a powerful diesel engine, but instead of connecting to a drive axle and transmission, as in a regular truck, the motor drives an advanced pump that pressurizes a tank of hydraulic fluid.

Upon acceleration, digital controllers send bursts of highly pressurized fluid via narrow pipes to pump motors, which set the wheels spinning. The system works in reverse during braking. The pumps act as generators, recapturing more than 70 per cent of the vehicle’s kinetic energy. At idle, the engine doesn’t run. Rather, it switches on and off intermittently to top up hydraulic pressure.

The design’s main attraction is that it consumes less energy. Using the diesel engine to generate hydraulic pressure, rather than propel the van, allows the motor to run at a fixed, optimal speed.

What’s more, the regenerative braking process is about 50 per cent more effective at recapturing energy compared with a Prius-style hybrid electric vehicle, Britt adds.

There are also secondary savings in the form of less wear and tear. Compared with conventional designs, UPS anticipates the brakes will last four or five times longer.

Likewise, running the engine at its “sweet spot” should extend its lifespan two- or three-fold compared with a diesel engine used conventionally, Britt says.

Given that a typical UPS brown delivery van has an average lifespan of up to 25 years, less day-to-day downtime means many more deliveries and lower lifetime operating costs.

Performance improves, too. Drivers like that the system delivers enormous torque – or pushing power – immediately. That’s an advantage when moving a 27,000-pound van up to speed, then back to a stop, scores of times every day. “Hydraulic power is really well suited to stop-and-go delivery routes,” says Britt.

The design is the result of a project that started in 2006, backed by the U.S. Department of Energy’s Clean Cities program.

In the six years since, the department has orchestrated the development of a series of pilot vehicles in collaboration with three vehicle manufacturers (Eaton, Parker Hannifin and FCCC) and three major shippers (FedEx, Purolator and UPS).

With a fleet of 93,000 delivery vehicles – running the gamut from big rigs down to three wheelers – UPS has proven itself an eager early adopter of green vehicle technologies. The hydraulic hybrids join a fleet of 2,500-plus “unconventional” vehicles, which includes HEVs, compressed natural gas (CNG), clean diesel and pure electric vehicles (EVs). Taken together, this fleet has motored more than 200 million miles since 2000.

The hydraulic hybrids are hitting U.S. roads at around $120,000 per vehicle, Britt estimates. That’s roughly twice as much as a standard diesel version. To help validate the long-term cost advantages, and to amass data on the real-world performance of the technology, the Environmental Protection Agency subsidized about a third of UPS’s total costs.

Britt believes there’s room for costs to fall and energy savings to rise. “If we do this right, we can set a standard for the whole industry.”

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At a Walkers Crisps factory in Leicester, England, PepsiCo is turning this soggy challenge into a water-saving innovation. The goal: to extract so much water from inbound spuds that the factory can go “off grid,” drawing little or no water from public taps. Doing so, PepsiCo hopes, will help save the plant roughly $1 million a year in avoided water costs.

“The idea for taking factories off the water grid came from a simple observation by our front-line teams that potatoes are 80 per cent water,” says Martyn Seal, PepsiCo’s European director of sustainability.

PepsiCo’s efforts to turn off the taps at its Walkers plant in the U.K. is one sliver of a bigger batch of initiatives to make its global operations run with less water. In 2010, the food-and-drink giant, which turned over $66.5 billion (U.S.) in sales last year, released its first comprehensive water report. The effort, similar to initiatives out of rival Coca-Cola, set out details of its water consumption alongside plans on how to use that water more productively.

One of its headline goals is to improve the efficiency of water use – measured by water consumed per unit of production – by 20 per cent by 2015, using 2006 as a baseline. PepsiCo hit this target last year, four years ahead of schedule. Another goal is to strive for “positive water balance” in water-distressed areas. This means for every unit of water PepsiCo uses, it strives to restore, replenish or prevent loss of the same amount or more in the same region. It also aims to provide access to safe water for three million people in developing countries before 2016.

Early on, potato-chip plants emerged as a juicy target for these goals. Making chips is surprisingly water intensive. In a normal year, some 350,000 metric tons of fresh tubers is shipped to the Leicester factory – the equivalent of some 13,000 tractor-trailer loads.

In the plant, potatoes are washed, peeled and sliced. A steady flow of H2O is used at each of these steps. In Leicester, this process demands roughly 700 million litres of water annually, the equivalent of roughly 280 Olympic-sized pools. Yet as crucial as water is while preparing the raw spuds, it’s an unwanted troublemaker thereafter. The thin slices are plunged for a few minutes into oversized fryers filled with oil boiling at 190°C (375°F). Water trapped in the potato slices vapourizes instantly, turning the otherwise inedible starch into an addictively crunchy treat.

In a conventional set-up, the cloud of steam that rises from these vats is vented out into the air. PepsiCo engineers recognized that the vapour represents a huge waste of both water and energy. To recover these wisps of moisture, PepsiCo fit a contraption onto the plant’s exhaust towers. Inside, the hot steam passes over a network of thin, cooled tubes. Moisture from the potato vapour condenses on the cooler tubes for easy collection. The process also recaptures traces of cooking oil from the exhaust. Both the oil and water can be reused. About four-fifths of the moisture that is normally lost is recovered.

Together with systems that recycle about two-thirds of the plant’s wastewater, the steam-recapture project is on track to supply enough water to hit PepsiCo’s goal of drawing zero freshwater in Leicester. The company is already testing the technology at similar sites in Holland and Belgium, part of a plan to extend these practices to other large European operations and, later, worldwide.

A successful pilot in the Leicester plant “will provide us with a technology suite that we will be able to reapply at other PepsiCo plants, particularly in areas of severe water scarcity,” Seal says. “This is an opportunity to realize meaningful cost savings while reducing our impact on the environment.”

Combined with other projects across PepsiCo’s operations, the steam-recapture efforts contributed to savings of $45 million in water and related energy costs last year, compared with the 2006 base when the company began these efforts. By volume, in 2011 it used 16 billion fewer litres of water, compared with 2006.

As much as PepsiCo execs crow about the bottom-line impact of these efforts, they point to strategic benefits too: The company must plan for operating risks that droughts pose to future operations. By 2030, global demand for freshwater could exceed supplies by 40 per cent, explains Dan Bena, PepsiCo’s senior director of sustainable development.

“If this gap is not closed, there will be no business as we know it today,” he says.

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Connected to Enbala’s smart-grid systems, water works is just the first category of big energy consumers that, by rapidly shifting when and how they use electricity, have the ability to help smooth out micro-fluctuations in the grid’s energy flows, displacing the fossil-fuelled generators that now perform this service. What’s more, Enbala’s software could boost renewable energy, too. It provides the kind of grid stabilization needed to help manage the variability of solar and wind energy as these sources make up more of the power mix.

Dizy’s vision is taking shape at a pumping station in Shire Oaks, south of Pittsburgh, Pennsylvania. That’s where American Water, the largest publicly-traded water and wastewater utility in the United States, is collaborating with Toronto-based Enbala. American Water has connected the pumps and compressors at its facility to Enbala’s smart-grid software, which can remotely turn the machines up or down to help keep supply and demand of electricity on the regional grid in constant balance. In the industry, this is called frequency regulation.

“Think of frequency regulation as a cruise control for the electric system,” explains Scott Baker, an analyst at PJM Interconnection, which manages a section of the U.S. grid spanning 13 states, plus the nation’s capital. To go a steady 60 mph, your cruise control imperceptibly adjusts gas and brakes to keep your speed constant. “Regulation services do the same thing, adding or reducing power on the grid to keep its frequency in balance,” says Baker. And like cruise control, which adds only spurts of gas or taps the brakes to control speed, regulation services require relatively small adjustments to do their job, with tiny doses of power added or consumed to stabilize frequency.

Conventionally, grid operators such as PJM have paid specialized generators to provide these balancing services. Because frequency regulation must be supplied in real time, all the time, these plants must be designed to be extra rugged, able to ramp up or down very quickly.

To be clear, regulation services are different from the so-called demand response. “You might call them distant cousins,” says Dizy. Demand response works when big energy consumers agree to switch off big users of power, with advance notice, for a few hours, a few times a year, when demand on the grid is greatest. On the other hand, regulation services are delivered on smaller scales, but are required 24 hours a day, every day, for minutes rather than hours, he explains.

Enbala’s solution turns the conventional approach on its head. Its software eliminates the need to generate electricity to balance the grid. It performs the same trick by managing electricity demand in real time. As such, the process can behave like a battery, Dizy notes. Rather than store energy in chemical form, as in a battery, Enbala describes its approach as “process storage,” where mechanical processes – such as filtering water – can be banked in advance of their use.

When, for instance, PJM needs a tiny increase in power use, Enbala requests that the pumps at American Water’s facility boost the flow of water into a holding tank by a few per cent. Or, if PJM needs power use to fall by a fraction, massive air pumps at the facility used to aerate wastewater treatment can be turned down. The adjustments are small – a few per cent up or down, for only a few minutes.

Enbala’s remote tweaking is designed to have no net effect on the water works’ processes. “At the end of the day, we’re just shifting when we use the power,” says Paul Gagliardo, manager of innovation development at American Water. Yet both companies earn a steady stream of payments from PJM for supplying the frequency regulation service.

The benefits for American Water have tallied up quickly. After less than a year working with Enbala, the water company reports that its total energy bill at the facility has fallen by two to three per cent. Happy with the outcome, it is now rolling out the system to 20 or so of its facilities.

Dizy’s company has identified many other industries that can provide regulation services by turning their processes up or down on the fly. “We’re just beginning to scratch the surface,” PJM’s Baker says.

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