26 U.S. Manufacturers Leading Sustainability

Above: Boston Metal has successfully commissioned its multi-inert anode Molten Oxide Electrolysis (MOE) industrial cell (pictured) for green steel production. This proves the scalability of the company's MOE technology for efficient steel decarbonization. Image Source: Boston Metal

Could a new industrial revolution save the planet? Industrialization brought with it many benefits, helping to raise the standard of living for vast segments of the population.

Unfortunately, the Industrial Revolution also brought with some long-lasting impacts we still struggle to manage. One of the most significant, of course, is industrial pollution, which has contributed so much to environmental degradation and climate change.

Climate change is one of the biggest issues facing the human race. Efforts to protect the environment have led to significant progress in wind and solar energy, hybrid and electric vehicles and reducing the amount of plastic in the environment.

Until recently, relatively little attention has been focused on the materials that we rely on for every product, building and vehicle on the planet.

Steel, aluminum, plastic, wood and glass all begin from natural elements or biomass. Producing these materials diverts roughly 40% of planetary land-based net primary production to human rather than natural use.This is the challenge facing scientists, engineers and manufacturers.

But innovative companies are now devising cleaner, greener manufacturing processes that can reduce carbon emissions. In honor of Earth Month, we’re exploring some of the top U.S. companies leading the way in sustainable manufacturing.

Sustainable Manufacturing Pioneer

Tesla, Inc. remains the world’s largest supplier of electric vehicles. A pioneer in sustainable manufacturing, Tesla was founded in 2003 with the mission to create “a car manufacturer that is also a technology company.” Tesla Motors has now achieved an annual run rate of one million electric vehicles and employs more than 70,000 workers.

The company is also a major developer of photovoltaic systems and lithium-ion batteries and has opened two new Gigafactories in Texas and Germany under the leadership of CEO Elon Musk. Telsa's flagship Gigafactory in the Nevada desert is roughly the size of 107 football fields or 13.6 million square feet to be exact, making it the largest factory in the world. This location produces car, home and commercial batteries and runs on 100% renewable energy.

Tesla is a well-known name in the electric vehicle market, but its sustainability vision goes beyond transportation. The company also produces solar panels, batteries and energy storage systems that enable homes and businesses to generate and use clean energy. Tesla's mission is to accelerate the world's transition to sustainable energy, and it has set ambitious goals to achieve this. For instance, it aims to produce 20 million vehicles per year by 2030, which would save about 4 gigatons of carbon dioxide emissions annually. Tesla also strives to source its materials responsibly, recycle its batteries and achieve net-zero carbon emissions across its operations.

Earth-Friendly Urban Manufacturing

Established in 2015, Method’s factory in Chicago’s historic Pullman district and is a prime example of earth-friendly urban manufacturing. Producing eco-friendly cleaning products, their facility features a wind turbine and three 35x35-foot solar tracking “trees” which follow the sun throughout the day to maximize energy generation.In addition, Method’s 75,000 square-foot roof is reserved for urban agricultural company Gotham Greens, which produces 500 tons of produce annually in a sprawling greenhouse.

Maintain Quality, Reduce Pollution

In an article on his blog GatesNotes, Bill Gates mentions the growth of developing nations contributing to carbon emissions as they begin to produce and utilize large quantities of concrete and steel.

Rather than unfairly limit their use, effectively resigning those nations to lower levels of development, Gates is optimistic that new, more natural materials can take the place of the ones that we have all become familiar with.

With a global demand in excess of two billion tons annually, steel production emits 7% of all greenhouse gases.

One company, Boston Metal, is experimenting with making steel using electricity rather than coal. Their process of choice, known as Molten Oxide Electrolysis, creates no greenhouse gases, uses no water and needs no toxic reagents.

This can help alleviate the impact that is created by current methods of production.

Take a look at Boston Metal's fascinating process for making steel in this video:

Novel Materials

Above: Eben Bayer and Gavin McIntyre
Co-founders of Ecovative (Photo Credit: Natt Phenjati).

 Opting for materials other than steel and plastic is of course a more direct way to limit their impacts. Organic and biofabricated materials promise higher strength, lower weight and negligible pollution at any point along their life cycle.

Modern Meadow, based in Nutley, New Jersey, designs cells at the DNA level that can be used to produce custom proteins which can vary in composition and properties when blended with other renewable materials.

Ecovative Design takes a slightly different approach by using mycelium, the root structure of mushrooms, to create their materials. They are able to literally grow structures rather than make components that are later assembled. This reduces waste during construction and assures biodegradability at the end of the product's life.

Ball Corporation: This packaging company has reduced its energy consumption by 13% and water usage by 10% since 2013, and has achieved an 80% recycling rate. It has also launched the Aluminum Stewardship Initiative (ASI) Certification, which sets standards for responsible production, sourcing, and stewardship of aluminum. Ball is a partner of The Recycling Partnership, which works to improve recycling infrastructure and education in the U.S.

Checkerspot, in Berkely California, uses microalgae fermentation to produce novel bio-based materials with unique properties, such as high-performance polyurethanes and textile finishes. This process reduces reliance on petroleum-based chemicals.

Bolt Threads creates innovative, bio-based materials like Mylo™ (a leather alternative grown from mycelium) and Microsilk™ (a protein-based fiber inspired by spider silk). These materials offer more sustainable alternatives to traditional textiles and animal products.

Plastic Elimination

Silicone has many properties that make it a perfect replacement for oil-based plastics. To that end, Stasher offers a line of reusable silicon bags that are also non-toxic.

Now, instead of storing food into disposable bags, individuals can store items in a Stasher Bag and avoid producing waste. Stasher Bags are microwave- and dishwasher-safe and capable of being used in ovens as well.

Ford Motor Company continues to promote environmentally-friendly auto parts by using recycled bottles for underbody shields on all cars and SUVs, and wheel liners on F-Series trucks. Altogether, the company uses 1.2 billion recycled plastic bottles per year—that’s roughly 250 bottles per vehicle on average.

Novoloop, of Menlo Park, California, has developed a chemical upcycling technology called ATOD™ (Accelerated Thermal Oxidative Decomposition) that breaks down plastic waste into high-performance chemicals and materials, which can then be used to create new products like footwear and automotive parts.

Biomason, a company based in Raleigh, North Carolina, utilizes bio-mineralization, a natural process inspired by coral reef formation, to grow cement and other construction materials. Their technology significantly reduces the carbon emissions associated with traditional cement production.

Powering Material Production

Gates also observes that switching to electricity for manufacturing steel and other products requires an energy conversion system that is measurably more efficient and cleaner than existing technologies.

And while billions of dollars have been invested into wind and solar, they lack the consistency and density required of heavy industry.

To this end, some designers have taken another look at nuclear power to overcome these limitations.

A company named TerraPower has developed a reactor that uses a traveling wave within the core that induces fission. This type of reactor can use nuclear waste products such as U-238 as fuel.

Thus, the concept has the potential to reduce the impact of two major problems; greenhouse emissions and nuclear waste.

Here are a few more examples of manufacturers taking uinnovative steps towards reducing pollution and emissions.

Electra (Boulder, CO): Electra is developing a process for refining iron ore using renewable electricity instead of fossil fuels. This technology has the potential to significantly decarbonize steel production, a major source of industrial emissions.

Twelve (Berkeley, CA): Twelve has created a catalytic technology that transforms captured carbon dioxide into valuable chemicals, fuels, and materials, such as jet fuel and polymers. This offers a pathway to utilize carbon emissions as a resource.

Fervo Energy (Houston, TX): While primarily an energy company, Fervo Energy's enhanced geothermal systems represent a sustainable and consistent power source for industrial facilities, reducing their reliance on fossil fuels. Their innovative drilling techniques make geothermal energy accessible in more locations.

Tackling emissions without sacrificing quality of life takes a lot of effort, but our future and our planet are well worth it.

Earth-Friendly Fashion

The Everlane clothing brand uses organic cotton, recycled materials, and transparent supply chains to minimize its environmental impact. Everlane has also launched ReNew, a collection of outerwear made from recycled plastic bottles, and ReCashmere, a collection of sweaters made from recycled cashmere. Everlane is a member of the Sustainable Apparel Coalition, which measures and improves the social and environmental performance of the apparel industry.

Recipe for a Greener Planet 

McCormick & Company Incorporated, a spice and flavor company has reduced its greenhouse gas emissions by 16% and water usage by 20% since 2015. It has also set ambitious goals to source 100% of its electricity from renewable sources by 2025 and to achieve net-zero carbon emissions by 2030¹. McCormick is committed to enhancing the lives of farmers and communities through its sustainable sourcing practices and social impact programs.

Sustainable Paints & Coatings

PPG is a global supplier of paints, coatings and specialty materials for various industries, such as aerospace, automotive, construction and consumer products. PPG's sustainability vision is to protect and beautify the world with its products and services. The company strives to reduce its environmental footprint by improving its energy efficiency, water consumption and waste management. PPG also develops eco-friendly products that help its customers save energy, reduce emissions and enhance durability. Additionally, PPG supports its employees' well-being and development, as well as various community engagement programs.

Industrial Suppliers Supporting Sustainability

• American Battery Solutions in Orion, Michigan produces lithium-ion batteries for the electric vehicle market.

• Cell-Con, Inc. in Exton, PA is a leading U.S. manufacturer of custom battery packs, including lithium-ion batteries.

• Dantona Industries in Wantagh, NY provides lithium polymer & lithium primary batteries as well as custom battery pack assembly.

• Ocean Organics provides organic and sea plant-based fertilizers and sea plant-based biostimulants.

• TRG, An Alter Co, has been providing quality metal recycling since 1890 and is the largest scrap metal processor in the state of Arkansas.

• Carefree Enzymes, Inc. manufactures natural enzyme products for the agricultural industry, hydroponic, and water gardening industries.

• CNI Manufacturing manufactures electric vehicle charging stations, among other products, in Irwindale, California.

• Neway Packaging is an eco-friendly packaging company that uses recyclable products and the focuses on eliminating waste and a reduced carbon footprint in all of their processes. Neway has recently announced a new partnership with Karopack's cardboard recycling program. 

 • Process equipment manufacturer Volkmann, Inc. has created a pneumatic vacuum conveying system to automatically capture unused or excess ingredients from a process and return them upstream for immediate reuse or return them to a hopper or container for reuse at a later date.

Related: Why You Should Partner With an Eco-Friendly Packaging Supplier 

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Editor's note: This article was originally published in April 2020. It is updated annually with new developments and top companies in sustainable manufacturing.