EnerSys wins 2024 U.S. Department of Energy Better Project Award

EnerSys, the global leader in stored energy solutions for industrial applications, has been awarded the Better Project Award from the U.S. Department of Energy (DOE) Better Plants Program for implementation of the Sovema Cold Cube cutting system. This award is the second award that EnerSys has received in two years from the DOE, underscoring the company’s commitment to sustainability, energy efficiency, and innovation within the manufacturing industry.

As a member of the Better Plants Program since 2021, EnerSys has continuously strived to enhance energy productivity, setting ambitious commitments with the Department of Energy to improve energy intensity by 25% by 2031.

The Sovema Cold Cube cutting system is a revolutionary advancement in lead battery manufacturing, eliminating the need for traditional energy-intensive lead heating, melting, and cooling processes. Instead, this innovative system utilizes a cold process to trim lead into cubes of necessary thickness directly from its solid state. By replacing the conventional gas fire process, EnerSys has significantly enhanced its sustainability efforts, simultaneously improving energy intensity and water intensity while prioritizing the safety and health of its employees.

Key benefits of the Cold Cube cutting system include:

  • Reduction in Embedded Scope 1 Carbon Emissions: EnerSys has achieved a substantial reduction of approximately 0.5 kilograms CO2e per battery produced, equating to a ~20% decrease in embedded Scope 1 emissions per battery.
  • Enhanced Worker Safety: The new process significantly reduces workers’ exposure to lead in the work environment, mitigating potential health risks associated with traditional manufacturing methods.
  • Water Conservation: EnerSys saves approximately 495,000 gallons of water per year at each site that uses the Cold Cube cutting system by eliminating the need for water cooling in the cube production process, contributing to water conservation efforts.
  • Environmental Impact: By eliminating the need for exhaust ventilation to remove lead fumes and the lead recovery process, EnerSys has reduced permitted environmental lead emissions to the atmosphere, while also decreasing lead waste by approximately 20,000 kilograms per year and saving approximately $15,000 annually.

Furthermore, the Cold Cube cutting system is replicable and being implemented at other EnerSys manufacturing facilities, extending its positive impact beyond its initial deployment.

Patrice Baumann, Chief Integrated Supply Chain Officer at EnerSys, commented, “Receiving the Department of Energy’s Better Project Award is a testament to our commitment to innovation and sustainability. The Cold Cube cutting system exemplifies our dedication to pushing the boundaries of what’s possible in energy-efficient manufacturing while prioritizing the safety and well-being of our employees.”

EnerSys remains steadfast in its mission to drive sustainable change within the industry, and the Cold Cube cutting system stands as a shining example of its ongoing efforts to lead by example and create a better, more sustainable future.