Sustainable Business

Case study Volkswagen 4/4 wind power – although we have some tornadoes of course. Under normal circumstances wind speed is not sufficient or consistent enough to implement wind technology. "We looked at landfill gas as there is a landfill around ten miles away, but both the quality and quantity were too low for it to be considered a long term prospect." Other environmental initiatives, however, have been undertaken at Chattanooga, in particular a rainwater harvesting system. Scherelis says: "We collect rainwater from the roofs and use them in our bathrooms and for cooling welding guns in our workshops." A second, "outstanding" technology – new to VW operations – is the dry scrubber system in use in the factory's paint shop. Gustashaw says VW's paint process is already significantly more energy-efficient than the industry average as the firm doesn't use a primer coat – the only manufacturer in the US not to, he says – eliminating the need for additional equipment. Gustashaw says: "We use a new paint process with a twofold advantage: improving the application technology and chemical constitution of the paint has made it possible to drop the primer coat while still maintaining the quality of the car paint at the same level. "With three paint layers we save one drying process and therefore about 20% energy." On top of this, the dry scrubber technology makes VW's paint operations more resource efficient. Scherelis says: "When you're painting a car, no matter how advanced the technology you use, there is at least 20% overspray – paint that doesn't hit the car. This is washed away with water, creating paint sludge, which is then pressed to minimise volume or heated to remove the water. "For the first time we are using an air stream to wash away the overspray, which is then mixed with limestone dust to create a material that can be used by the cement industry, saving 20,000 gallons [90,921 litres] of water a day and meaning we do not produce any toxic waste in our workshop." But, regardless of certification, technology and renewable energy generation, it is the people that will really make the difference says Scherelis: "We wanted to produce a clean car in a clean factory. And it is the people who are really behind the concept of a green car. "You can do everything technically possible to minimise impacts, but if staff do not turn off lights, switch off engines, or do not close water faucets, you won't achieve your goals. "Our team here is very environmentally aware, which is essential, because you can have any number of technical aids to improved environmental performance, but in the end it depends on the man running the machine."

• Cover