Andersen Corporation 2004 APR View/Print

OMB No. 2010-0032
Expiration Date 08/30/06

2004 Performance Track Annual Performance Report

Andersen Corporation
A050030
Year 1 Annual Performance Report
Member Since 2001 (2nd Member Term)

SECTION A: GENERAL FACILITY INFORMATION

A.1

Name of your facility:

Andersen Corporation

A.2

Name of your parent company:

Andersen Corporation

A.3

Facility contact person for the Performance Track program:

Name:	Mr. Jeff R. Nelson
Title:	Supervisor - Chemical Health and Safety
Phone:	(651) 264-7456
Fax:	(651) 264-5089
Email:	jeff.nelson2@andersencorp.com

A.4

Facility location:

Street Address:	100 Fourth Avenue North
Address Cont:
City:	Bayport
State:	MN
Zip Code:	55003-1096
Mailing address (if different from above):
Mailing Address:
Address Cont:
City:
State:
Zip Code:
If your facility has multiple street addresses, please list any other addresses for its sites or buildings.

A.5

Facility's website address (if any):

http://www.andersenwindows.com

A.6

Number of employees (full-time equivalents) who currently work in the facility:

More than 1,000

A.7

North American Industrial Classification System (NAICS) Code(s) that is(are) used to classify business at the facility:

321911

A.8

In your application and, perhaps, in previous annual performance reports, you described what your facility does or makes. Have there been any (additional) changes to your facility's list of products and/or activities?

If yes, please list them here:

A.9

Have the environmental requirements applicable to your facility changed during this reporting period?

If yes, please describe these changes here:

Section B: ENVIRONMENTAL MANAGEMENT SYSTEM

B.1.a	When was an EMS assessment last conducted by an independent party at your facility?
	2004
	If an assessment was conducted during 2004, please provide the type (e.g., ISO 14001 certification), the scope, and the month(s) of each assessment.

Type Scope Dates

External attorney audit

Compliance documentation, EMS compliance
March 2004

B.1.b When was an internal EMS assessment last conducted at your facility?

2004

If an assessment was conducted during 2004, please provide the scope and month(s) of each assessment.

Scope Dates

Perma-Shield Casement/Awning Business Unit - Compliance & conformance to procedures
  March  2004

Patio Door Business Unit - Compliance & conformance to procedures
  April  2004

General & Andersen Extrusion Business Units - Compliance & conformance to procedures
  May  2004

Double Hung Window Products Business Unit - Compliance & conformance to procedures
  September  2004

B.1.c When was an internal or corporate compliance audit last conducted at your facility?

2004

If an audit was conducted during 2004, please provide the scope and the month(s) of each audit, and indicate who conducted the audit(s) (e.g., facility staff, corporate groups, third party). (Don't include audits, inspections, or site visits by regulatory or external organizations).

Scope Dates Who conducted the audit

Perma-Shield Casement/Awning Business Unit - Waste & chemical labeling, permit compliance (air, waste water, NPDES, storm water, hazardous waste, spill response, UST/AST, SARA)
  March  2004 Corporate staff & outside attorneys

Patio Door Business Unit - Waste & chemical labeling, permit compliance (air, waste water, NPDES, storm water, hazardous waste, spill response, UST/AST, SARA)
   April  2004 Corporate staff & outside attorneys

General & Andersen Extrusion Business Units - Waste & chemical labeling, permit compliance (air, waste water, NPDES, storm water, hazardous waste, spill response, UST/AST, SARA)
  May  2004 Corporate staff & outside attorneys

Double Hung Window Products Business Unit - Waste & chemical labeling, permit compliance (air, waste water, NPDES, storm water, hazardous waste, spill response, UST/AST, SARA)
  September  2004 Corporate staff & outside attorneys

B.1.d (Optional) If you would like to describe any other audits or inspections that were conducted at your facility, please do so here.

Washington County hazardous waste inspection was conducted at Andersen Bayport facility on January 21, 2004.

B.1.e Briefly summarize corrective actions taken and other improvements made as a result of your EMS assessments and compliance audits.

We increased inspections of nonhazardous waste labeling. We have developed a training plan to ensure ongoing training and EMS training of new hires.

B.1.f Has your facility corrected all instances of potential non-compliance and EMS non-conformance identified during your audits and other assessments?

Yes

If no, please explain your plans to correct these instances.

B.1.g When was the last Senior Management review of your EMS completed?

February  05

Who was the senior manager present at the review?

Name: Mr.  Jim Humphrey

  Title: President/CEO

B.2.a ISO 14001 Certification. Is your facility currently certified to ISO 14001?

No

B.2.b Is your facility a Responsible Care-certified facility?

No

B.3 Environmental Aspects Identification. When did your facility last conduct a systematic identification and/or review of your environmental aspects?

August 04

SECTION C: ENVIRONMENTAL PERFORMANCE RESULTS

C.1 COMMITMENT 1

Andersen Corporation's first commitment is to reduce the facility's VOC emissions.

C.1.a Briefly describe your activities and achievements related to this commitment or, if relevant, any circumstances that delayed progress this year.

VOCs increased in 2004 at a rate slightly higher than total window & door units shipped (normalizing factor). This increase in total units shipped was meant to apply to the facility as a whole, and did not account for individual variations in different processes that emit VOCs. One of the primary reasons for the VOC increase was significant growth in customer demand for finished interior units, which requires twice as much paint as painted exterior only units. Our normalizing factor may not necessarily reflect these changes in demand mix. However, we continue to focus and work on process efficiency improvements and pollution prevention projects in order to decrease future VOC emissions

C.1.b Please report your facility's actual performance.

Performance Data

Baseline Year 1 Year 2 Year 3 Performance

Calendar Year 2003 2004 2005 2006 Commitment Units

Actual Quantity (per year) 1,391 1,465 n/a Tons

Specify other:

C.1.c Normalized progress toward goal.

Normalized Total Baseline Year 1 Year 2 Year 3 Perform.
Goal Units

Normalizing Factor 1.0 1.032

Normalized Quantity 1,391 1,419.57 1,182 Tons

Specify other:

Basis for your Normalizing Factor:
Units shipped (mostly windows & doors)

C.1.d Please list any other EPA voluntary programs to which you are reporting these data.

Project XL

C.2 COMMITMENT 2

Andersen Corporation's second commitment is to improve the management of the facility's non-hazardous waste, specifically wood milling by-product containing trace amounts of non-hazardous contaminants.

C.2.a Briefly describe your activities and achievements related to this commitment or, if relevant, any circumstances that delayed progress this year.

Early in 2004, we identified a higher value use for the wood milling by-product which was the intent of our goal. This material (3,493 tons) was provided to another firm for use as an absorbent product.

C.2.b Please report your facility's actual performance.

Performance Data

Waste Management Method Baseline Year 1 Year 2 Year 3 Units

2003 2004 2005 2006

Landfill

Specify other:
4,076 1,192 Tons

Specify other:

Other off-site management

Specify other: Finding end markets, higher value uses, waste-to-energy
0 0 Tons

Specify other:

Reused/recycled off-site

Specify other:
0 Tons

Specify other:

Specify other: Air Emissions and POTW Discharge

Specify other:

Specify other:

Specify other:

C.2.c Summarized progress toward goal.

Actual Total Baseline Year 1 Year 2 Year 3 Perform.
Goal Units

Total Non Hazardous Waste 4,076.00 1,192.00 n/a Tons

Specify other:

Normalized Total Baseline Year 1 Year 2 Year 3 Perform.
Goal Units

Normalizing Factor 1.0 1.032

Total Non Hazardous Waste 4,076.00 1,155.04 4,076.00 Tons

Specify other:

Basis for your Normalizing Factor:
Units shipped (mostly windows & doors)

C.2.d Please list any other EPA voluntary programs to which you are reporting these data.

C.3 COMMITMENT 3

Andersen Corporation's third commitment is to reduce the generation of, and improve the management of, the facility's hazardous waste.

C.3.a Briefly describe your activities and achievements related to this commitment or, if relevant, any circumstances that delayed progress this year.

Paint processes were further optimized. Process changes improved paint transfer efficiency and reduced paint flush solvent waste.

An off-site recycling program was implemented for paint flush solvent waste. Recovered solvent is returned to our facility for reuse.

C.3.b Please report your facility's actual performance.

Performance Data

Waste Management Method Baseline Year 1 Year 2 Year 3 Units

2003 2004 2005 2006

Other off-site management

Specify other: Fuel Blending
375 201 Tons

Specify other:

Other off-site management

Specify other: Recycled Off-Site/Reused On-Site
0 67 Tons

Specify other:

Specify other:

Specify other:

Specify other:

Specify other:

Specify other:

Specify other:

C.3.c Summarized progress toward goal.

Actual Total Baseline Year 1 Year 2 Year 3 Perform.
Goal Units

Total Hazardous Waste 375.00 268.00 n/a Tons

Specify other:

Normalized Total Baseline Year 1 Year 2 Year 3 Perform.
Goal Units

Normalizing Factor 1.0 1.032

Total Hazardous Waste 375.00 259.69 290.00 Tons

Specify other:

Basis for your Normalizing Factor:
Units shipped (mostly windows & doors)

C.3.d Please list any other EPA voluntary programs to which you are reporting these data.

NA

C.4 COMMITMENT 4

Andersen Corporation's fourth commitment is to reduce the facility's total (non-transportation) energy use.

C.4.a Briefly describe your activities and achievements related to this commitment or, if relevant, any circumstances that delayed progress this year.

Energy efficiency and improvements continue to be a main focus. Types of projects implemented include lighting retrofits, equipment replacement, building management systems and chiller optimization projects. Lean manufacturing has had a significant impact on eliminating inefficiences in electrical, diesel, and propane use. Of note, 2004 was a mild winter compared to 2003, which may have lessened the facility heat load.

NOTE-EXPLANATION OF CHANGES:
Section C.4.b, updated "Steam" under "Energy Generated Off-Site": 2003 baseline = 219,332 MMBtu, 2006 goal = 208,365 MMBtu. (This was updated as a result of reconciling our 2003 utility bills in late April 2004.)
Section C.4.b, added "Biomass" data to "Energy Generated On-Site". (This was added because the on-site steam category was deleted by EPA. The biomass energy produces the on-site steam.)

Section C.4.c, deleted "heating/cooling degree days" under "Basis for your Normalizing Factor."

C.4.b Please report your facility's actual performance.

Performance Data

Baseline Year 1 Year 2 Year 3 Units

Calendar Year 2003 2004 2005 2006

Energy Generated Off-Site

Electricity 346,564 337,690 MMBtus

Specify:

Steam 219,332 208,502 MMBtus

Specify:

Total Energy Generated Off-Site 565,896.00 546,192.00 MMBtus

Sources of Energy Generated On-Site

Coal

Specify:

Natural Gas 51,073 47,952 MMBtus

Specify:

Crude Oil

Specify:

Fuel Oil

Specify:

Diesel 7,461 6,652 MMBtus

Specify:

Propane/LPG 8,426 6,758 MMBtus

Specify:

Gasoline

Specify:

Hydrogen Powered Fuel Cells

Specify:

Natural Gas/Methane Powered Fuel Cells

Specify:

Biomass 187,108 165,561 MMBtus

Specify:

Solar

Specify:

Wind

Specify:

Landfill Gas

Specify:

Geothermal

Specify:

Hydroelectric

Specify:

Other Fuel or Source
Specify:

Specify:

Total Energy Generated On-Site 254,068.00 226,923.00 MMBtus

Total Renewable Energy Use 206,862.15 184,809.33 MMBtus

Total Non-Renewable Energy Use 613,101.85 588,305.67 MMBtus

Total Energy Use 819,964.00 773,115.00 MMBtus

Metric Tons of CO₂ Equivalents 79,275.64 77,017.10 MTCO2E

Metric Tons of CO₂ Equivalents Offset Through Purchases of Electricity from Renewable Off-Site Sources MTCO2E

Net Metric Tons of CO₂ Equivalents 79,275.64 77,017.10 MTCO2E

C.4.c Summarized progress toward goal.

Actual Energy Use Total Baseline Year 1 Year 2 Year 3 Perform.
Goal Units

Total Energy Use 819,964.00 773,115.00 n/a MMBtus

Net Metric Tons of CO₂ Equivalents 79,275.64 77,017.10 n/a MTCO2E

Normalized Energy Use Total Baseline Year 1 Year 2 Year 3 Perform.
Goal Units

Normalizing Factor 1.0 1.032

Total Energy Use 819,964.00 749,142.44 778,966.00 MMBtus

Specify other:

Net Metric Tons of CO₂ Equivalents 79,275.64 74,628.97 75,311.91 MTCO2E

Specify other:

Basis for your Normalizing Factor:
Units shipped (mostly windows & doors)

C.4.d Please list any other EPA voluntary programs to which you are reporting these data.

None

Progress Towards Other Significant Aspects of your EMS

In the table below, please provide a narrative summary of progress made toward EMS objectives and targets other than those reported as Environmental Performance Commitments. You may limit the summary to environmental aspects that are significant and towards which progress has been made during the reporting year. Do you have additional environmental aspects to report?Yes

Environmental Aspect Progress Made This Year (e.g., quantitative or qualitative improvements, activities conducted)

Recycling of Hazardous Waste
We began shipping our paint flush solvent to the solvent supplier's TSD facility to be recycled. We shipped 13,310 gallons of solvent and received back 5,060 gallons for reuse.

Reduction in Material Usage

We reduced wood adhesive purchases by 10,349 gallons due to improvements in the application process.

Reduction in Material Usage

We reduced wood consumption by 500,000 board feet by improving efficiency in the continuous gluing process.

Attachments (if applicable) :

SECTION D: PUBLIC OUTREACH AND PERFORMANCE REPORTING

D.1 Please briefly describe the activities that your facility conducted during the year to interact with the community on environmental issues and to report publicly on environmental performance.

Continue to conduct periodic Community Advisory Committee meetings and provide mailings of environmental updates to the local community via a publication titled 'Andersen Community Update'.

D.2 Please indicate which of the following methods your facility plans to use to make its Performance Track Annual Performance Report available to the public. Please check all that apply.

Meetings, Press Releases, Community Advisory Panel, Other
Please Specify Other:Environmental brochure entitled 'Environmental Goals and Progress'

Attachments (if applicable):

OMB No. 2010-0032

SECTION E: SELF-CERTIFICATION OF CONTINUED PROGRAM PARTICIPATION

The U.S. Environmental Protection Agency is not yet in a position to accept electronic signatures and therefore requests a faxed, signed copy of the Section E page. Please complete Section E online, then print Section E using the link on the Overview page.Section E should be signed by the senior manager of your facility and faxed it to the Performance Track Information Center at (617) 354-0463.
On behalf of Andersen Corporation, I certify that: I have read and agree to the terms and conditions as specified in the National Enviromental Performance Track Program Guide. This facility, to the best of my knowledge, continues to meet all program criteria; I have personally examined and am familiar with the information contained in this Annual Performance Report. The information contained in this report is, to the best of my knowledge and based on reasonable inquiry, true, accurate, and complete; My facility has an environmental management system (EMS), as defined in the Performance Track EMS criteria, including systems to maintain compliance with all applicable federal, state, tribal, and local environmental requirements, in place at the facility, and the EMS will be maintained for the duration of the facility's participation in the program; My facility has conducted an objective assessment of its compliance with all applicable federal, state, tribal, and local environmental requirements; and the facility has corrected all identified instances of potential or actual noncompliance; and Based on the foregoing compliance assessments and subsequent corrective actions (if any were necessary), my facility is, to the best of my knowledge and based on reasonable inquiry, currently in compliance with applicable federal, state, tribal, and local environmental requirements. I agree that EPA's decision whether to accept participants into or remove them from the National Environment Performance Track is wholly discretionary, and I waive any right that may exist under any law to challenge EPA's acceptance or removal decision. I am the senior manager with responsibility for the facility and am fully authorized to execute this statement on behalf of the corporation or other legal entity whose facility is part of the National Environmental Performance Track program.
Signature/Date:	______________________________________________________
Name:	Ms. Mary Schumacher
Title:	Sr. Vice President-RTQ & E
Phone Number:	651-264-5632
E-Mail Address:	mary.schumacher@andersencorp.com
Facility Name:	Andersen Corporation
Facility Street Address:	100 Fourth Avenue North Bayport, MN 55003-1096
Mailing Address:	,
Performance Track ID#:	A050030

Type	Scope	Dates
External attorney audit	Compliance documentation, EMS compliance	March 2004

B.1.b	When was an internal EMS assessment last conducted at your facility?
	2004
	If an assessment was conducted during 2004, please provide the scope and month(s) of each assessment.

Scope	Dates
Perma-Shield Casement/Awning Business Unit - Compliance & conformance to procedures	March 2004
Patio Door Business Unit - Compliance & conformance to procedures	April 2004
General & Andersen Extrusion Business Units - Compliance & conformance to procedures	May 2004
Double Hung Window Products Business Unit - Compliance & conformance to procedures	September 2004

B.1.c	When was an internal or corporate compliance audit last conducted at your facility?
	2004
	If an audit was conducted during 2004, please provide the scope and the month(s) of each audit, and indicate who conducted the audit(s) (e.g., facility staff, corporate groups, third party). (Don't include audits, inspections, or site visits by regulatory or external organizations).

Scope	Dates	Who conducted the audit
Perma-Shield Casement/Awning Business Unit - Waste & chemical labeling, permit compliance (air, waste water, NPDES, storm water, hazardous waste, spill response, UST/AST, SARA)	March 2004	Corporate staff & outside attorneys
Patio Door Business Unit - Waste & chemical labeling, permit compliance (air, waste water, NPDES, storm water, hazardous waste, spill response, UST/AST, SARA)	April 2004	Corporate staff & outside attorneys
General & Andersen Extrusion Business Units - Waste & chemical labeling, permit compliance (air, waste water, NPDES, storm water, hazardous waste, spill response, UST/AST, SARA)	May 2004	Corporate staff & outside attorneys
Double Hung Window Products Business Unit - Waste & chemical labeling, permit compliance (air, waste water, NPDES, storm water, hazardous waste, spill response, UST/AST, SARA)	September 2004	Corporate staff & outside attorneys

B.1.d	(Optional) If you would like to describe any other audits or inspections that were conducted at your facility, please do so here.
	Washington County hazardous waste inspection was conducted at Andersen Bayport facility on January 21, 2004.
B.1.e	Briefly summarize corrective actions taken and other improvements made as a result of your EMS assessments and compliance audits.
	We increased inspections of nonhazardous waste labeling. We have developed a training plan to ensure ongoing training and EMS training of new hires.
B.1.f	Has your facility corrected all instances of potential non-compliance and EMS non-conformance identified during your audits and other assessments?
	Yes
	If no, please explain your plans to correct these instances.

B.1.g	When was the last Senior Management review of your EMS completed?
	February 05
	Who was the senior manager present at the review?
	Name: Mr. Jim Humphrey
	Title: President/CEO

B.2.a	ISO 14001 Certification. Is your facility currently certified to ISO 14001?
	No
B.2.b	Is your facility a Responsible Care-certified facility?
	No

B.3	Environmental Aspects Identification. When did your facility last conduct a systematic identification and/or review of your environmental aspects?
	August 04

Andersen Corporation's first commitment is to reduce the facility's VOC emissions.
C.1.a	Briefly describe your activities and achievements related to this commitment or, if relevant, any circumstances that delayed progress this year.
	VOCs increased in 2004 at a rate slightly higher than total window & door units shipped (normalizing factor). This increase in total units shipped was meant to apply to the facility as a whole, and did not account for individual variations in different processes that emit VOCs. One of the primary reasons for the VOC increase was significant growth in customer demand for finished interior units, which requires twice as much paint as painted exterior only units. Our normalizing factor may not necessarily reflect these changes in demand mix. However, we continue to focus and work on process efficiency improvements and pollution prevention projects in order to decrease future VOC emissions
C.1.b	Please report your facility's actual performance.

Performance Data
	Baseline	Year 1	Year 2	Year 3	Performance
Calendar Year	2003	2004	2005	2006	Commitment	Units
Actual Quantity (per year)	1,391	1,465			n/a	Tons Specify other:

Normalized Total	Baseline	Year 1	Year 2	Year 3	Perform. Goal	Units
Normalizing Factor	1.0	1.032
Normalized Quantity	1,391	1,419.57			1,182	Tons Specify other:
Basis for your Normalizing Factor:	Units shipped (mostly windows & doors)

C.1.d	Please list any other EPA voluntary programs to which you are reporting these data.
	Project XL

Andersen Corporation's second commitment is to improve the management of the facility's non-hazardous waste, specifically wood milling by-product containing trace amounts of non-hazardous contaminants.
C.2.a	Briefly describe your activities and achievements related to this commitment or, if relevant, any circumstances that delayed progress this year.
	Early in 2004, we identified a higher value use for the wood milling by-product which was the intent of our goal. This material (3,493 tons) was provided to another firm for use as an absorbent product.
C.2.b	Please report your facility's actual performance.

Performance Data
Waste Management Method	Baseline	Year 1	Year 2	Year 3	Units
Waste Management Method	2003	2004	2005	2006	Units
Landfill Specify other:	4,076	1,192			Tons Specify other:
Other off-site management Specify other: Finding end markets, higher value uses, waste-to-energy	0	0			Tons Specify other:
Reused/recycled off-site Specify other:		0			Tons Specify other:
Specify other: Air Emissions and POTW Discharge					Specify other:
Specify other:					Specify other:

Actual Total	Baseline	Year 1	Year 2	Year 3	Perform. Goal	Units
Total Non Hazardous Waste	4,076.00	1,192.00			n/a	Tons Specify other:

C.2.d	Please list any other EPA voluntary programs to which you are reporting these data.

Andersen Corporation's third commitment is to reduce the generation of, and improve the management of, the facility's hazardous waste.
C.3.a	Briefly describe your activities and achievements related to this commitment or, if relevant, any circumstances that delayed progress this year.
	Paint processes were further optimized. Process changes improved paint transfer efficiency and reduced paint flush solvent waste. An off-site recycling program was implemented for paint flush solvent waste. Recovered solvent is returned to our facility for reuse.
C.3.b	Please report your facility's actual performance.

C.3.d	Please list any other EPA voluntary programs to which you are reporting these data.
	NA

Andersen Corporation's fourth commitment is to reduce the facility's total (non-transportation) energy use.
C.4.a	Briefly describe your activities and achievements related to this commitment or, if relevant, any circumstances that delayed progress this year.
	Energy efficiency and improvements continue to be a main focus. Types of projects implemented include lighting retrofits, equipment replacement, building management systems and chiller optimization projects. Lean manufacturing has had a significant impact on eliminating inefficiences in electrical, diesel, and propane use. Of note, 2004 was a mild winter compared to 2003, which may have lessened the facility heat load. NOTE-EXPLANATION OF CHANGES: Section C.4.b, updated "Steam" under "Energy Generated Off-Site": 2003 baseline = 219,332 MMBtu, 2006 goal = 208,365 MMBtu. (This was updated as a result of reconciling our 2003 utility bills in late April 2004.) Section C.4.b, added "Biomass" data to "Energy Generated On-Site". (This was added because the on-site steam category was deleted by EPA. The biomass energy produces the on-site steam.) Section C.4.c, deleted "heating/cooling degree days" under "Basis for your Normalizing Factor."
C.4.b	Please report your facility's actual performance.

Actual Energy Use Total	Baseline	Year 1	Year 2	Year 3	Perform. Goal	Units
Total Energy Use	819,964.00	773,115.00			n/a	MMBtus
Net Metric Tons of CO₂ Equivalents	79,275.64	77,017.10			n/a	MTCO2E

Normalized Energy Use Total	Baseline	Year 1	Year 2	Year 3	Perform. Goal	Units
Normalizing Factor	1.0	1.032
Total Energy Use	819,964.00	749,142.44			778,966.00	MMBtus Specify other:
Net Metric Tons of CO₂ Equivalents	79,275.64	74,628.97			75,311.91	MTCO2E Specify other:
Basis for your Normalizing Factor:	Units shipped (mostly windows & doors)

C.4.d	Please list any other EPA voluntary programs to which you are reporting these data.
	None

D.1	Please briefly describe the activities that your facility conducted during the year to interact with the community on environmental issues and to report publicly on environmental performance.
	Continue to conduct periodic Community Advisory Committee meetings and provide mailings of environmental updates to the local community via a publication titled 'Andersen Community Update'.
D.2	Please indicate which of the following methods your facility plans to use to make its Performance Track Annual Performance Report available to the public. Please check all that apply.
	Meetings, Press Releases, Community Advisory Panel, Other
	Please Specify Other:Environmental brochure entitled 'Environmental Goals and Progress'
	Attachments (if applicable):