Toll upgrades Nike warehouse to be wholly carbon neutral

Toll’s custom-built Nike warehouse in Melbourne’s Altona North has become the first-ever facility in Australia to achieve a whole-of-building carbon neutral certification under the National Carbon Offset Standard (NCOS).
Toll said certification of the Toll-Nike logistics facility, owned by Stockland, caps off its significant investment in energy efficiency at the site, which was named Best Industrial Project at the National Energy Efficiency Awards in 2017. The site’s energy efficiency program featured upgrades to a 2.5 kilometre long conveyor system that is powered by 145 individual electric motors, and the retrofitting of 1,300 light fixtures with high-efficiency LED. This has led to a halving of the site’s total electricity consumption, exceeding the greenhouse reductions required by NCOS.
The site has also received a Green Star Performance rating, the first Green Star rating for Nike and Toll, and the first in Stockland’s Logistics portfolio.
Nike’s operations director Marie Varrasso said the success of the facility reflects the company’s commitment to reducing its carbon footprint while delivering efficient products and savings that can be passed on to its customers directly.
“Through this collaboration continuous improvements have been introduced into the supply chain, which ultimately benefits Nike’s footwear, apparel and equipment customers. It’s a unique relationship, with innovation at the heart of everything we do,” said Ms Varrasso.

Toll Global Logistics president Chris Pearce said it was the partnership between Toll, Nike and Stockland that made the carbon neutral certification and Green Star rating possible.
“Toll and Nike’s partnership began when this facility was built in 1999. It was the first distribution centre to be built by Toll’s specialised warehousing division and, at the time, this type of supply chain asset was virtually non-existent in the market.
“It’s fitting that almost 20 years on, Nike, Toll, and Stockland have been awarded this landmark certification – a testament to our continuous innovation. This is a milestone achievement for all and demonstrates our collective commitment to reducing environmental impacts and introducing smarter, more sustainable solutions across our operations,” added Mr Pearce.

The Toll-Nike facility provides specialised warehousing, picking and dispatch capable of handling more than 27,000 stock keeping units (SKU) and two million units of stock. The 18,000 sqm warehouse and fit-out were designed with environmental efficiency in mind and features:

  • Translucent roof sheeting – to maximise daylight so warehouse lighting can be switched off when ambient light is sufficient.
  • Energy-efficient lighting systems –powered by the latest LED technology suited to Nike’s warehousing needs. The system also improves visibility and safety, and motion sensors have been fitted to limit power usage to occupied areas.
  • Roof insulation – to assist with temperature control.
  • An optimised conveyor system –rewired and reprogrammed to operate in relation to product volumes, eliminating unnecessary movement.

Toll and Nike have offset the remaining greenhouse emissions generated by the building by investing in forest conservation projects in Tasmania as well as in an energy recovery waste water treatment plant in Thailand. These projects protect local biodiversity and native species support jobs in local communities and reduce greenhouse gas emissions.

Toll commended for warehouse energy efficiency

Toll Group’s custom-built Nike warehouse in Altona North, Melbourne, has been named Best Industrial Energy Efficiency Project at the National Energy Efficiency Awards 2017.
The National Energy Efficiency Awards recognise excellence in energy efficiency across Australia.
Toll won Best Industrial Energy Efficiency Project for its recent upgrade to the Toll-Nike facility, which provides specialised warehousing, picking and dispatch solutions capable of handling more than 27,000 stock keeping units (SKUs) and two million units of stock.
The upgrade, completed in May 2017, included the rewiring and reprogramming of the facility’s 2.5km conveyor system and 145 electric motors and upgrading 1,300 light fittings to high-efficiency LEDs. The re-engineered and streamlined supply-chain processes reportedly removed waste and reduced energy use by 54 per cent.
“We see environmental sustainability as our corporate responsibility and we’re committed to reducing our environmental footprint,” said Mark Jones, Sustainability and Energy Manager, Toll Group. “Through Toll’s Smarter Green program we are introducing smarter, more sustainable solutions across all of our operations.
“Technology has advanced significantly since Toll and Nike embarked on our supply-chain partnership almost 20 years ago. We’ve been working closely with Nike to introduce ‘smarter green’ innovations and this award is a welcome tribute to our lean journey,” said Jones.
The 18,000m2 warehouse and fit-out include energy-efficient lighting systems that improve visibility and safety, translucent roof sheeting, roof insulation, and an optimised conveyor system.
Ian Black, Outbound Manager, Nike Pacific, said, “The change to LED lighting in our warehouse has been a great initiative and a real win-win situation. We have reduced our carbon footprint and our electricity costs while improving the quality of our lighting. We commend Toll for sourcing an effective, efficient solution and driving the result.”
Toll’s Jones added that plans to have the facility certified carbon neutral are now under way.
“As part of the certification process, Toll will look to have the facility certified under the National Carbon Offsets Scheme and rated by the Green Building Councils Green Star rating system,” said Jones. “We’re also keen to replicate the success of this project at other Toll-Nike locations in future.”

Industry professionals convene in Texas for Automation Fair

Houston, in Texas, became the hub of the automation world recently when more than 9,700 manufacturing and industrial professionals gathered for the Automation Fair event, hosted by Rockwell Automation and its PartnerNetwork members. 

The two-day event has attracted manufacturing and process business leaders, industry analysts, and technology and service providers from the industrial sector who are eager to capitalise on the most promising trends in automation and process control. 

This year’s 22nd annual event also marks the 110th anniversary of the founding of Allen-Bradley, the flagship brand of automation equipment from Rockwell Automation. 

“By showing how attendees can converge automation and information into one connected enterprise, the event enables customers to improve their business profitability, help optimise their plants, and make their operations cleaner, safer, more secure and more energy-efficient,” said Keith Nosbusch, chairman and CEO, Rockwell Automation.

Automation Fair featured hands-on labs, demonstration workshops, technical sessions, industry forums and more than 100 exhibitors showcasing cutting-edge products and solutions. 

Attendees of the Process Solutions User Group meeting heard about best practices and discovered solutions to improve their processes and create new revenue. 

Rick Esker, senior director, Industry Solutions Group at Cisco, shared how companies can balance big data and industrial security. Industry experts from Endress+Hauser, Acuite and Rockwell Automation shared the latest technology trends affecting the connected enterprise for instrumentation, human-machine interface, and production information, and how they can help drive performance.

Process professionals were invited to hear more than 16 educational sessions and to offer input on the prioritisation of future developments to the PlantPAx process automation system from Rockwell Automation. 

Attendees from 31 customer companies – in industries ranging from life sciences to oil and gas – discussed their experiences using the PlantPAx system and other process solutions. 

Industry analysts and journalists joined Rockwell Automation for the half-day global media forum Automation Perspectives, focusing on the theme of “Leveraging Technology to Transcend Industrial Business Barriers.”

Keith Nosbusch of Rockwell Automation gave the keynote address. He discussed how the adoption of standard IP-based Ethernet is revolutionising industry and enabling truly connected enterprises – leading to sustainable competitive differentiation with optimised plants and supply networks.

Following Nosbusch, industry leaders discussed the risks and rewards of this connectivity. Attendees learned about the importance of protecting industrial control and SCADA systems, and key elements in implementing an effective security strategy. 

A second group of speakers then discussed the unprecedented transformation of the global energy landscape, and how innovations in automation, intelligent motor control, remote services and delivery expertise in turnkey solutions are helping improve asset management in energy industries.

SCLAA receives energy efficiency information grant to assist supply chain and logistics SMEs in Australia

The Supply Chain and Logistics Association of Australia (SCLAA) has received a grant of $743,310 from the Department of Resources, Energy and Tourism to develop and deliver a comprehensive and targeted program for Australian transport and logistics SMEs.

The Supply Chain, Transport and Logistics sector is a high energy consumer. However, there are significant opportunities for improving energy efficiency and reducing energy costs including reduction in the usage of electricity, all types of fuels and refrigerants as well as optimisation of transport, loads, materials handling, cold chain logistics, scheduling and other efficiencies.

David Rogers, Chairman – SCLAA indicated that SMEs in the supply chain and logistics industry face time and competitive pressures and lack the targeted skills and resources to identify and improve their energy use, which in turn would benefit their business productivity.

The Energy Efficiency Solutions project will deliver a comprehensive closed loop program for SCLAA members and other SMEs in the supply chain and logistics sector. The program will equip SCLAA’s substantial membership, contacts and 409,756 SMEs across Australia who warehouse, distribute and/or transport goods, with targeted tools, resources and training tailored specifically to improve their energy efficiency. The program will be delivered at 30 locations in every State and Territory across Australia and all components will be available online.

Outlining the 7-stage program, Mark Skipper, National Director – SCLAA explains that Stages 1 – 6 will be completed by July 2014 and Stage 7 by December 2014. All content will be available on the SCLAA website at least until the end of 2021.

Stage 1

Research and stakeholder consultation

Stage 2

Creation of a web-based ‘Energy Efficiency Assessment tool’ to assist SMEs benchmark their energy performance against industry best practice, and understand where key opportunities to improve energy efficiency exist within their business.

Stage 3

Based on the outcomes of Stage 1, creation of comprehensive workshop packs of tools and resources to assist time- and resource-poor SMEs to take action on energy efficiency.

Stage 4

Promote the project through existing channels to build awareness about the project across the sector and inform SMEs how they can benefit environmentally and financially by participating.

Stage 5

Deliver half to full day workshops in all 8 State and Territory Capital Cities, plus 22 regional locations in every State and Territory across Australia in addition to 10 interactive webinars, where participants can also ask questions in real time and learn from other similar businesses.

Stage 6

Workshop content and recordings will be made available online to maximise reach to SMEs who are unable to participate in a workshop or a webinar.

Stage 7

Follow up all participants for three and six months after stage 4 or 5. Ensure benchmarks are being bettered and that each SME has a strategy to reduce energy consumption.

Skipper adds that ClimateWorks Australia, a not-for-profit organisation will be SCLAA’s project partner. ClimateWorks has an extensive track record, and their knowledge and capability will ensure the success of the project for SCLAA members and the 400,000+ SMEs in the supply chain and logistics industry.

Image: Mark Skipper

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