With an environmental management system rigorously tailored to the unique aspects of flooring industry, we are increasing efficiency and reducing its environmental impacts for energy, water, emissions, solid waste and pollution prevention. Through these efforts and additional business management strategies, such as Six Sigma and LEAN manufacturing, we have committed to significant improvements within our facilities including:

  • Energy intensity reduction by 25 percent by 2017
  • Waste to landfill reduction by 90 percent by 2011
  • Water intensity reduction by 40 percent by 2016

Alternative Fuels

Philly Queen Commercial's parent company, Shaw, is leading the carpet industry in its efforts to identify alternative fuel sources to power its manufacturing and transportation systems. As Shaw pursues strategies to reduce its reliance on oil-based energy, it is establishing innovative alternatives such as Reclaim-to-Energy technology.

Reclaim-to-Energy turns reclaimed carpet and carpet waste into energy to power two of its carpet manufacturing facilities. The Reclaim-to-Energy facility was completed in 2010 and is expected to convert more than 76 million pounds annually of reclaimed carpet into steam and energy for the manufacturing site. Using post-consumer carpet as an energy source is one of Shaw’s strategies to reduce its use of petroleum-based energy while increasing the company’s use of alternative energy sources. In fact, Shaw is committed to using 10 percent alternative energy by 2017. Reclaim-to-Energy will deliver 90 percent of the facility’s energy – or 50 thousand pounds of steam per hour.

Shaw’s first gasification, alternative fuel-to-energy facility, created in partnership with Siemens Building Technologies in 2005, was the first in the carpet industry. By replacing traditional oil boilers, Shaw is converting approximately 36 million pounds of pre-consumer carpet and wood manufacturing byproducts into steam energy. The waste streams are stored in two separate silos, mixed, and then sent to the gasifier. The waste is then turned into a synthetic gas, which powers a boiler that generates 50,000 pounds of steam per hour.

Reclaim-to-Energy:

  • Improves plant emissions
  • Conserves natural resources
  • Diverts over 76 million pounds of carpet waste from landfills annually
  • Diverts approximately 6,000 tons of wood waste from landfills annually
  • Other alternatives like yellow grease are contributing to our conservation efforts. Yellow grease is collected from food preparation.
  • After it is cleaned, it can be used to power boilers in our manufacturing facilities, reducing our reliance on oil.

Transportation

Innovations in how we deliver our products are increasing efficiency in our transportation fleet. With one of the largest private trucking fleets in the U.S., we are participating in the EPA's SmartWays Transport Partner Program, a voluntary collaboration between the EPA and members of the freight industry. The program centers on increased transportation efficiency while reducing greenhouse gases and air pollution. Through this program, Shaw will document the 72 million miles its fleet travels annually and analyze the results with the EPA. Participation in SmartWay shows our commitment to reducing emissions.

Environmental Management System

Increasing operating efficiency is a major way that we are reducing our impact. We monitor our processes through the Shaw Environmental System, our specialized environmental management system that monitors and reduces our energy, water, emissions and waste. This system is modeled after the requirements of ISO 14001 while tailoring to fit the specific needs of a carpet manufacturer. All of our commercial carpet manufacturing plants are certified through the SES. Additionally, our carpet tile facility is certified through ISO 14001.

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