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Key departmental publications, e.g. annual reports, budget papers and program guidelines are available in our online archive.

Much of the material listed on these archived web pages has been superseded, or served a particular purpose at a particular time. It may contain references to activities or policies that have no current application. Many archived documents may link to web pages that have moved or no longer exist, or may refer to other documents that are no longer available.

KODAK (Australasia) Pty Ltd
Cleaner Production - Achieving Better Lighting by Rationalising and Refurbishing Existing Fittings

Kodak (Australasia) Pty Ltd successfully implemented a cleaner production initiative in a building, which was used to fabricate plastic and metal products. The initiative raised illumination levels by 128 percent while lowering electricity use by 30 percent. The changes involved cost $21,350, had a direct payback period of 3.8 years, and substantially improved the working environment.

Background

Kodak (Australasia) Pty Ltd manufactures and distributes photographic and multi-media products and services to markets throughout Australia, Asia and the Pacific.

The wholly-owned subsidiary of Eastman Kodak Company in the US, the Australian operation has headquarters in Melbourne and employs over 2,000 people across Australia. One of just twelve Kodak manufacturing plants worldwide, the company is Australia's sole producer of film and paper for the photographic industry.

Almost 80 percent of production is exported each year, primarily to Asian and Pacific rim countries. During the decade of the 1990's, Kodak exported $3 billion worth of Australian-made product to South East Asia, making it one of the country's top exporters of high-technology goods.

The Process

Kodak Australasia fabricated plastic and metal products in a building which had a three metre high ceiling, was originally lit by fluorescents, and in which lighting levels were half those required to properly carry out the fabrications. The old light fittings were causing maintenance problems with leaking capacitors and a high failure rate of control gear.

Cleaner Production Initiative

Kodak was able to transform lighting conditions in the building by implementing recommendations made by consultants aimed at rationalising and refurbishing existing fittings.

To achieve better lighting at lower cost, Kodak replaced the existing control gear with low-loss ballasts and new capacitors, and with electronic ballasts in many of the fittings. Reflectors were cleaned and replaced. Tri-phosphor lamps were used to replace fluorescents.

Because of its concern about the environmental impact of disposing of over 800 lamps, Kodak collected all the old fluorescent lamps and disposed of them in a lamp recycling machine, which recovers glass, metal and mercury for reuse.

Advantages of the Process

The new tri-phosphor lamps put out more light, produce better colour and last longer than conventional fluorescents. By keeping the 400 existing fittings, costs were reduced.

As a result of the changes, illumination levels were raised by 128 percent, and electricity use was lowered 30 percent (equivalent to a reduction of COČ emissions of 29.3 tonnes). The changes involved cost $21,350, had a direct payback period of 3.8 years, and substantially improved the working environment.

The cost savings more than justified the lighting upgrade. Due to the success of the project, Kodak immediately made similar changes to the building's basement warehouse.

Cleaner Production Incentive

Poor lighting levels were hindering fabrication operations and old light fittings were causing serious maintenance problems.

Barriers

No barriers were experienced in implementing the recommendations made by the consultants.

Further Developments

The building in which the lighting initiative was first implemented has since been demolished, although the upgraded lighting system has been saved to potentially be reinstalled in their current metal products fabrication area.

A comprehensive environmental management system has been developed at the manufacturing plant in Coburg, driven corporately towards continuous improvement.  ISO 14001 accreditation was achieved in 1999.

Contact

Ron Guest
Health, Safety and Environment Group
Kodak (Australasia) Pty Ltd
PO Box 90
Coburg VIC 3058
Ph: (03) 9353 3247
Fax: (03) 9353 3258
Email: rguest@kodak.com

Casestudy implementation: 1997
Casestudy initially prepared: May 1998 by the Environment Management Association of Australia (EMIAA)

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Last modified: May 2001