Green finishing: the use of landfill gas in BMW's Greer, S.C. plant is creating the world's first "green" paint shop.

BMW Manufacturing Co., LLC, Greet, S.C., is no stranger to environmental initiatives. The company is a charter member of the U.S. Environmental Protection Agency's (EPA) National Environmental Achievement Track, which recognizes companies for their environmental stewardship and performance. It is also a member of the South Carolina Environmental Excellence Program and is on the Dow Jones Sustainability Group Index, which rates environmentally friendly companies. When the EPA approached BMW Manufacturing in 2000 about operating a large, on-site cogeneration system using recycled methane gas generated by the Palmetto Landfill near Spartanburg, S.C., BMW Manufacturing readily agreed. A pipeline was constructed the nine miles from the landfill to the plant, and the cogeneration system successfully began producing electricity for the facility in 2003. It was an environmentally responsible project.

But the company is also in business to make a profit. Like other companies that rely heavily on natural gas for manufacturing operations, BMW Manufacturing has been concerned about the volatility of natural gas prices over the last several years. In late 2004, the plant assigned a team to identify energy conservation strategies, particularly for its paint shop, which was the largest overall consumer of energy in the facility. The team worked closely with Durr Systems, …