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New Brazilian Factory Showcases Design for the Environment
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| Minimal-energy-use principles were followed in the design of John Deere's new Montenegro, Brazil, tractor factory. |
(November 27, 2007) – John Deere's new Montenegro, Brazil, tractor factory, which began operations in October, is an example of how to build a factory with respect for the environment.
About 25 percent of the 961,233-square meter (265-acre) building site is maintained as undisturbed nature habitat. Marshlands, native trees and wildlife habitat were preserved during construction. Trees listed by Brazil as protected flora were carefully relocated. Disturbance to the land was minimized through the tree relocation and by planting four trees for every one that was removed during construction.
Native materials like stone were incorporated in the design of the factory's office area. Roof skylights and windows increase natural light within the 61,000-square-meter (658,190-square foot) factory. Minimal-energy-use principles were followed to select energy-efficient motors, lighting design, and the facility's energy management systems, and construction materials such as adhesives and paints were carefully selected with the environment in mind. Non-ozone-depleting potential refrigerants, like R-134a, are used for the cooling systems. All of these attributes have led to a low energy design and a low greenhouse gas footprint.
Outside the factory, a retention pond controls storm water runoff. Buses pick up and drop off commuters at designated loading and unloading areas, and parking areas for buses are included in the site design.
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| Windows and roof skylights increase natural light within the 61,000-square-meter factory. |
Wastewater is treated on-site and recycled to water vegetation, minimizing the use of potable water for irrigation. There is no underground oil or chemical storage tanks at the site and no floor drains. Groundwater monitoring wells have been installed to assure this pristine environment is maintained.
The factory uses low-emission paints, and water curtain technology to control paint-booth emissions. No chemicals containing the heavy metals nickel, zinc and chromium are used in the paint pre-wash processes. This allows the paint system, the factory's major source of industrial wastewater, to purify its wastewater through an ultrafiltration membrane unit, which is a non-chemical treatment technology, rather than sending it to the local treatment facility.
The coolant from machining operations is closely managed to extend its life before being properly treated and recycled. All metal filings and particles are removed and recycled. "We expect no wastewater discharges from the factory site except for infrequent batches of spent machine coolant and ultrafiltration concentrate—only two to four truckloads every six months," said Liping Zhang, Deere & Company environmental engineer.
Other metal scrap, paper, wood, and plastics are transported to a separate waste storage building on site, where they are sorted and shipped to recyclers, Zhang said.
Dan McConaghy, Manager, Facilities Engineering at Deere & Company, said the new facility is the work of a multi-national design and construction team, a joint effort of John Deere Brasil employees, Brazilian designers, and engineers from the corporate engineering staff at John Deere's world headquarters in Moline, Illinois.
"The environmental design results are a world-class success for the environment, employees and citizens," McConaghy said.
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