The National Renewable Energy Laboratory (NREL) in Colorado has developed some technological breakthroughs that will change the way we manufacture solar cells. The lab is sponsored by the Department of Energy and the new breakthroughs could not only save costs and reduce the environmental impact of producing “eco-friendly” power sources, but this innovations will also make the United States far more competitive with other nations when it comes to alternative energy parts manufacturing.

The NREL’s big breakthrough last month was that they found a way to produce the first solar cell that is able to produce more electrons than it gathers form the sun—making solar energy production go farther.

Equally innovative and even more exciting for solar energy products manufacturers is the lab’s development of a process for creating solar cells that will reduce the energy cost of producing the cells by up to 50%–which means less cost to the manufacturer of the cells in terms of their own electric bill, and perhaps more accessible alternative energy for all of us once those savings translate into a cheaper form of solar cell and more affordable production of solar energy products.

And not only are these cells cheaper to produce—they run more efficiently to, a product of the more efficient production process, which removes impurities in the silicone as the heat forms the cells.

These types of breakthroughs in the US are continued good news to a manufacturing economy that has found new ways to compete with international competitors in Asia and the euro zone. Although America has always been a heavy importer of parts (even on the products it manufactures in the country) there has been a recent trend toward more US production of parts as well as increased manufacturing overall in the U.S.

We take the recycling to the curb knowing basically one thing: they’ll take this bin of recyclable goods away and magically turn it into new products. But many people don’t think of recycling as what it truly is: a manufacturing process.

After the plastics are picked up from the recycling bin, they are separated from the other products, which go through similar processes. Plastic is inspected to make sure it is the right type and all non-processable materials have been removed.

After inspection, plastic is sent for further processing where it is chopped into small pieces and then washed using biodegradable soap products and water. These pellets are similar to traditional plastic pellets in that they can be melted down and used in a variety of plastic manufacturing projects.

The plastic pellets are sorted by type and color and are distributed for the production of new products. Because the new products will be made out of the recycled plastic pellets, it is likely that they will also be recyclable, unless the plastic is compromised by having secondary types of plastic added to it.

If the new products are recyclable, they will go back through the same process again at the end of their life. Although this cannot completely eliminate the need for new plastic, it significantly reduces the quantity of demand for plastic.

The manufacturing process used in recycling plastics is not entirely free of waste and not every element of it can be considered “environmentally friendly” because the recycling process uses high levels of electricity and water. That being said, the manufacturing process for new plastic is arguably worse, so continuing to improve the recycling process is the most sustainable bet for future plastics products manufacturing.

Innovation and production are crucial and important parts of our economy and lifestyle in the twenty-first century. In fact, many of our manufacturing processes create a more efficient system than we had even fifty years ago. Whether insulating industrial processes, controlling the flow of precious resources, creating a repair for a failing product rather than creating an entire replacement or just producing high quality consumer products that will last the user a long time, good manufacturing is both necessary and environmentally friendly.

But that doesn’t meant the entire industry engages in “green” practices all the time. In fact, some of the most basic (but least necessary) aspects of producing and distributing a manufactured product can be changed or eliminated to make costs lower—both financially and environmentally.

Responsible manufacturing lets our world grow

Paper Use
We’re quickly entering a paperless age, and manufacturing companies should be no exception. With product lines changing as quickly as they do with new technology and innovation, it almost seems silly to print catalogs that will need to be thrown out and revised less than month later. Websites are easy and quick to update and can reach consumers faster and translate into more new business. Similarly, paper promotional mailings are easy for the consumer to misplace or forget about. E-mail and other electronic forms can efficiently reach consumers and create a sense of accessibility between the consumer and your product.

Water Use
Fresh water is quickly becoming one of the most precious but least protected resources in the world. Water costs are starting to go up and will continue to do so in the coming years. Investing in a water recycling system and efficient appliances and machinery will save you money and reduce your ecological footprint.

Product Recycling
Want repeat business? Take a clue from the British carpeting manufacturing business. Many of these companies have started a program where they use old carpet, reprocess it and incorporate it into new carpet. This is a great way to reduce their raw material costs and consumers can bring back old, dingy carpet and use it as credit toward newly fabricated carpet. This is good business and also good sense when it comes to making the most of raw materials. Using them again and again in new products, when possible, can save you and your consumer money.