Cascade Engineering – Designing Toward Function, Planet, and People
Created in 1973, Cascade Engineering specializes in large-part plastic injection molding. The second-generation, woman-owned company was recognized at the 2023 Society of Plastics Engineers Automotive Innovation Awards for its work with Ford Motor Co. on the Mega Bin/Frunk for the Ford F-150 Lightning. Frunk is a portmanteau word for a trunk on the front of a vehicle. In doing so, it converted the front trunk from a compression-molded painted sheet-molding compound to a large Class A composite injection-molded part and is currently one of the industry’s largest injection-molded product pieces. SBND interviewed Christina Keller, CEO and chair of the Grand Rapids-based Cascade Engineering Family of Cos., about the frunk’s impact on sustainability, creating circular economy solutions, and evolving trends in the industry. Q: How does sustainability stand out within Cascade Engineering? A: Cascade is a second-generation family business that is woman-owned and sustainable. We are celebrating 50 years as a triple-bottom-line company. We are a certified B Corp, ISO 14001 certified and LEED certified. Our focus is on innovative products and solutions in manufacturing and we supply to the furniture, automotive, and waste industries. Q: What role does sustainability play in the company? A: We have been organized as a triple-bottom-line – people, planet, profit – company since our inception. On the people side, we work heavily with returning citizens and also on initiatives to reduce the state of recidivism in Michigan. On the planet side, we’ve been zero waste to landfill since 2012 and have innovated a number of projects in the circular economy. Obviously, we must be profitable to engage in all these activities. Q: Can you tell us more about the frunk? I believe this is currently the industry’s largest injection molded product piece. What aspects of this impact sustainability? A: First, by eliminating the paint process there is a significant reduction of Volatile Organic Compounds (VOCs). Second, it’s more fuel efficient due to decreased product weight. Next, the manufacturing process has been streamlined to reduce energy. And finally, it’s more recyclable in that the end-of-life material can be recycled into a variety of products. Q: How do you think this impacts Southeast Michigan? A: The paint process takes place in Ford facilities, so eliminating this directly reduces VOCs in Southeast Michigan. The collaboration between Cascade and Ford serves as a promising example of potential collaborations between Tier One suppliers and manufacturers in Southeast Michigan. There are many opportunities for partnerships toward a better environmental outcome. Q: In what other ways does the frunk’s design and manufacturing process impact sustainability? A: We have eliminated the environmental burden of paint in the Frunk’s design. Additionally, the secondary routing of holes has been eliminated, reducing process steps and allowing us to produce a higher quantity of parts in less time. The seal interfaces are integrated into the assembly station for further efficiencies, and the material used is recyclable. Q: The Frunk process utilizes a 4,000-ton injection press and a tool equipped with a 16-drop hot runner system to mold these parts. Is this typical? A: No. The use of a 4,000-ton injection press is unique in the industry. The capital required to purchase this equipment poses a significant barrier for most companies. Additionally, the specialized human capital needed to operate such a large press is rare. Q: Is the new frunk product in production? A: Yes. If you buy a Ford 150 Lightning today you will get one of these pieces in your vehicle. It is fully in production and we are looking at more innovations currently. Q: What new innovations are you working on? A: Additional frunks in the near term. Before electric vehicles, we did not have the space in the front of vehicles to create a front trunk. Now, with increased demand for EVs, it’s a growing area and we are looking at manufacturing a number of additional front trunks. Q: Does being in Michigan in particular post challenges or opportunities in terms of your work on the sustainability front? A: There is an excellent network of manufacturers in Michigan – especially Southeast Michigan – that allows us to be truly innovative. A challenge is finding talent. This sector overall currently has 516,000 job openings and over the next decade is projected to reach 3.8 million. Another challenge we face is incarceration. The U.S. has one of the highest incarceration rates, with 1 in 100 adults in jail. We see returning citizens as a valuable pool of talent that can be trained and integrated into the workforce. This presents a unique opportunity for Michigan, as the state is not attracting enough new residents, and only 50% of college graduates stay here. Additionally, while college graduates remain in their first job for an average of two years, returning citizens tend to stay for seven years. This approach offers an interesting solution to addressing the talent gap in Michigan. Q: How do you see industry trends evolving? A: I see a lot of work in the AI space and Industry 4.0 focused on innovative manufacturing methods. There is a noticeable trend towards reshoring, driven by the constraints observed in the global supply chain during the pandemic. Companies are now striving to establish a local footprint, which also helps reduce the carbon footprint from transportation. Additionally, significant efforts are being made to maximize package density for more efficient shipping and transportation. Regarding talent attraction and retention, we have more 65-year-olds in the U.S. than ever before, while our younger demographic is declining. Q: How is Cascade adapting to the changes in the industry? A: We are constantly scanning the horizon to look at trends. On the sustainability side, we are developing an ecosystem of recycled plastic sources to enhance our clean stream of recyclable materials. We are looking at streams from medical waste that could be used, and post-consumer and post-industrial applications. We are also working on additives to use in our products such as hemp fibers, dust waste, and trash materials. And finally, we are working with
30-Year Architecture Firm Looks Toward Sustainability in Design
Hamilton Anderson Associates (HAA) sits in the heart of what was once Harmonie Park and is now Paradise Valley – and has since the architecture firm’s start in 1994. Its doctrine is to ‘design sustainable communities that inspire change,’ and this encompasses not only architecture, but interior design, landscape architecture, urban design and planning, and development services. The firm was founded by Rainy Hamilton Jr. and Kent Anderson. SBN Detroit spoke to Hamilton about the firm’s sustainability focus and impact on Southeast Michigan. Q: Tell me about HAA as it relates to sustainability A: This is a big topic. Overall, we are always looking to have a positive impact on our clients’ projects and ultimately their bottom line. We always strive to have their best interests in mind and toward that, we need to be cognizant of the design approach, and how we can spend their funds wisely and thoughtfully. We incorporate products and materials that can be recycled or have been recycled, and that are manufactured locally, whenever possible. We think about how we can craft design solutions that take into account the environment and the planet – such as how we can include passive energy generation like wind and solar power. Also, how we manage stormwater is a significant topic with large impervious areas such as roofs and surface parking areas. All of these things are embedded in our thought process for every project. Q: Has HAA always had a focus on sustainability? A: Yes. As trained architects, it has become more commonplace over the last several decades to have this mindset around sustainability. We have been trained to push for well-crafted design solutions that minimize the impact on the environment. We are conscious of utilizing renewable resources such as lumber. Reforesting serves to replenish these natural resources when done properly. At Hamilton Anderson, sustainability is built into our design processes. It is in our DNA to minimize the impact of building on Earth and be sensitive to the environment. Q: Your website says that HAA designs sustainable communities that inspire positive change. Will you elaborate on this? A: In very simplistic terms, let’s think about a typical day. If we can craft our public rights-of-way to be rich and beautiful with adequate lighting and thoughtful landscaping when people move through these areas their spirits are lifted. You feel a very different reaction if you walk through an area with no investment, no landscaping, and no thought or work put into beautifying the space. These types of conditions can negatively impact one’s psyche. Good design is good business. We want to create places of work, rest, and play toward the best possible experience. Q: What are some examples of this? A: We were excited to be part of the design team for Little Caesars Arena. The urban design solution implemented recessed the seating bowl down below grade to reduce the overall height of the facility on the street. Building elements such as retail outlets and other activities were placed around the bowl and the exterior facades were articulated in varying ways to create a wonderful street environment. The result is an active, energized Woodward Avenue with wonderful streetscapes. As we travel the Woodward Corridor, there are many HAA projects that have been completed and have contributed to the growth of Detroit. Projects include the Wayne State Welcome Center, the Addison Hotel, the Strathmore Hotel, Crystal Lofts, Woodward Place, Hamilton at Midtown, Woodward West, Detroit School of Arts, and City Modern. Our work on the Hudson’s Tower with the Bedrock team involves enhancing the downtown area with this major new landmark building and thinking about how it intersects the ground plane and surrounding streetscapes. We rode by the Port Authority Building the other day that we designed on the Detroit River. We suggested a second floor be added to what was originally going to be a one-story structure. Now, there is a gathering event space on top that takes full advantage of the riverfront views. This banquet and meeting space has had a positive impact on the Port Authority’s bottom line and has enhanced the visitor experience. We are thrilled to be working on the expansion of the Music Hall and how to craft this new building next to the historic Music Hall. This addition will enhance the hall and will shine as a beacon welcoming visitors into this vibrant district. Q: How does developing the economy in Southeast Michigan come into play in your work? A: The projects we help bring to fruition and the overall momentum happening in Detroit play a huge role in sustaining and advancing the economy in Southeast Michigan. When I think about the Henry Ford Health right in Midtown, we are proud to be part of the design team. We are influencing how this large development meets the ground plane and embraces the surrounding community. This is critical for the success of this project. The sheer number of jobs this project will create is good for the city and enhances the future of healthcare in Detroit and Southeastern Michigan. All of this will enhance the livability of our city. Over our thirty years of practice, I’ve seen development and construction blips occur in Detroit. Large projects begin and end and there have been development lulls in between. But now we have momentum. We are seeing sustained growth on many fronts. We are seeing new housing and sustained growth occur that is fueling our economy. Q: How important is choosing suppliers and partners that also have a sustainability focus? A: Very important. We work with many different engineering consultants that follow best practices for sustainable design. Many of our contractors are LEED Certified and employ sustainable practices in constructing projects. Q: What are your biggest challenges? A: We are having difficulty finding professionals to grow our practice. We are currently a firm of 40 professionals and are looking to grow but struggling to find the right team members. Also, quality assurance is critical. We practice internal
Rockford Construction – Focusing on the Full Life Cycle of Spaces
From real estate development to construction and property management, Rockford Construction has been serving the commercial, multiunit, educational, industrial, healthcare, and retail markets throughout the Midwest for more than 30 years. How do they approach sustainability? Mike VanGessel, founder and CEO of Rockford Construction, shares that and more with SBN Detroit. Q: Please tell us about the sustainability practice you have in place. A: Rockford’s current sustainability efforts reflect a “triple bottom line” that is focused on people, the planet, and profit. We consider ourselves to be good stewards of all three of these finite resources. This is certainly a broader view than many people take, but one that is important to our clients and our communities. And we’re not just a construction company. We also develop, own, and manage properties, so our focus extends across the full life cycle of space – not just the initial resources during construction, but the total cost of ownership and the impact our buildings make into the future. As a result, our efforts are quite broad. But each building type brings its own set of challenges and opportunities, allowing us to customize our approach and maximize value to our clients. Q: When did your focus on sustainability come about? A: Decades ago. Rockford was an early adopter of sustainable construction practices. We knew that buildings were a major driver of energy consumption at that time. As a company committed to delivering value to our clients, we recognized that achieving greater energy efficiency would also decrease long-term costs. As the sustainability movement evolved and our knowledge of healthy buildings has grown, our efforts have expanded to include things like water conservation, low VOC (volatile organic compounds)-emitting materials, locally sourced and rapidly renewable materials, and more. Our more-recent triple bottom line approach recognizes that “people” and “profit” are also finite resources, as we’ve seen in our current economy. The shortage of workers – not just in construction but in most industries – has driven a focus on a construction process and end-user facilities that are highly efficient, productive, and attractive to people. The reduction of waste in time and money allows those resources to be deployed elsewhere. Q: What are some examples? A: Over the years, Rockford has completed hundreds of projects that are LEED certified or designed to meet certification requirements. But our approach is applied to all our projects, exploring the building design, systems, and materials to determine the right solution based on client needs, first costs, and long-term operational expenses. The most successful projects result from early involvement and clear goal-setting. One of the best examples can be found in Circuit West, a cutting-edge energy district that encompasses a 13-block area in Grand Rapids. As Rockford was developing and constructing buildings in the area, we partnered with Consumers Energy in their effort to pilot next-generation energy technology. Together, we installed 1,800 solar panels and battery storage capable of producing 500 kilowatts every hour. Power lines were buried, and solar arrays were installed in conjunction with other construction work, greatly reducing installation costs. The result is more reliable, renewable energy for the neighborhood. While Circuit West was a large-scale effort, early involvement allows us to explore all possibilities, uncovering those that make the greatest impact on our clients’ triple bottom Line. Q: What are the drivers behind these practices? A: The driver of sustainability is simple. We are creating healthier, more energy-efficient, and cost-effective buildings for our clients and the people who will live, work, play, and heal inside of them. In the early days, sustainable design and materials were thought to drive additional costs to buildings, and owners had to be deeply committed. Today, a better understanding of good design, appropriate systems, and more readily available sustainable and renewable materials are all driving cost savings. Why a client chooses sustainable solutions – cost savings, environmental responsibility, or healthy spaces – isn’t important. What matters is that the result helps us conserve resources and positively impact our world. Q: Rockford services so many different industries and types of construction – how do your sustainability practices differ between projects? A: Each project is unique, and clients have different goals and expectations. That said, best practices can vary based on different project types. For example, some industrial buildings are high users of energy and, at times, water. Energy-efficient systems, water conservation, and grey water options can provide good solutions. In healthcare facilities, research shows that healing environments include natural light, views, good ventilation, low VOC products, and easily cleaned materials. By focusing on what makes each building unique, the low-hanging fruit of sustainability becomes clear. Often, the most sustainable building is the one that is renovated, either for its existing use or for a new one. This is particularly true in an urban setting, where many building exteriors were built to last for decades. By reusing the walls and structure, not only are tons of waste materials diverted from landfills, but owners can capture the value of materials already in place. Warehouses can be converted into apartment buildings, churches become office buildings and schools are reimagined into senior living. Over the years, Rockford has developed expertise in the adaptive reuse of space. Q: Do you have a team of people set up to implement your sustainability practices? A: In the past, the Rockford team included a director of sustainability. However, we wanted to turn what could be described as a “program” into a “practice.” Our construction team and our property and facility managers are all well-versed in sustainable practices. But we have a variety of team members, from accountants to graphic designers, who want to be a part of our company-wide efforts. That’s why we are launching a company-wide Sustainability Committee to continue to expand our impact both internally and externally. Q: Beyond vendors and material choices – what else do you look at? A: Locally sourced talent, vendors, and materials are part of a strategy that is appealing to our clients, who strive to support
Huntington Place Detroit – Green and Working Toward Greener
What was Cobo Hall opened its doors as one of the nation’s first mega-conference centers in 1960 and has served as a venue for sports teams, concerts, speakers, and more. In fact, on June 23, 1963, following the Detroit Walk to Freedom civil rights march, Martin Luther King Jr. delivered the original version of his “I Have a Dream” speech at Cobo Arena. Having under gone a $279 million renovation in 2015, and several name and sponsorship changes since, Huntington Place Convention Center now features a 30,000-square-foot, three-story glass atrium overlooking the Detroit riverfront, the largest ballroom in Michigan at 40,000 square feet, and 723,000 square feet of exhibit space. That’s a lot of space to maintain, and sustain. The facility also is the largest and only convention center in the world certified under LEED v4.1 Operations and Maintenance (O+M), as well as Michigan’s largest certified green LEED Building. The facility contributes 9.8 tons of unserved food to Forgotten Harvest and sends 66 tons of compost annually to Hammond Farms and also has 110 recycle bins, 10,000 square feet of green roof, five beehives that retain 10,000 bees, and numerous awards for its green efforts. How did it get here, and what can other businesses and nonprofits glean from their work in this area? Cedric Turnbore, director of operations and chair of the Huntington Place Green Committee, shares his insights on where to begin when approaching a sustainability program, the why behind it, and some examples of initiatives Huntington has put into place to date. WHERE SHOULD A BUSINESS START? #1: Form a Committee “In 2011, we developed the Green Team, a committee that includes one person from each department in the office building,” Turnbore says. “We meet regularly to review programs and goals.” The center also has a 5-person executive board established by the state of Michigan to oversee its sustainability efforts. “The board acts as our governing body that oversees and approves our programs. We work closely with them to set and manage budgets and ensure that initiatives are in the best interest of the facility, the employees, our guests, and the city.” #2: Set Attainable Goals “Start with the low-hanging fruit,” Turnbore said. “Things you can achieve in the near-term that will help to gain traction for the long haul.” Initial goals of the Green Committee in 2011 included growing the committee with representation from each department and vendor partner and organizing operations around the Green Venues Michigan certification. Since the United Nations set for 17 Sustainable Development Goals in 2015, Huntington Place has patterned its work around them. When the TCF Center Green Committee reconvened in September 2021 after a COVID-related hiatus, those goals were front and center. “This will be pivotal year for our sustainability program,” Karen Totaro, general manager TCF Center/ASM Global, said at the time. Our work in the center is to contribute to the United Nations Sustainable Development Goals and re-certify as the largest LEED venue in Michigan will be front and center for our efforts in 2022. Turnbore said so far the center has been able to implement projects contributing toward 13 of the 17 goals, and the work will continue. #3: It Takes Green to Go Green “Businesses must commit to funding for the necessary equipment, tools, and programming,” says Turnbore. “That’s why we have a board … to govern and approve our spends and ensure that those spends have the desired outcome – a return on the investment.” Some examples of investments Huntington Place has made include 110 recycling stations, food court waste diversion receptacles, visitor education posters, a green roof, receptacles for compost collection, trash compactors, a cardboard baler, and a green website page for visitor information. #4: It’s a Marathon, Not a Sprint “When we first launched our efforts 11 years ago, many individuals thought it was a fad. That the sustainability work would ‘go away. You need to have a long-term plan to ensure that it never goes away and be steadfast in your efforts every single day. It’s as simple as that,” says Turnbore. #5: Educate! According to Turnbore, for their efforts to be impactful, it’s imperative to continually educate employees, vendors, and visitors on the how and the why behind them. To that end, every new employee is trained on conservation and sustainability during onboarding. Information is posted throughout the facility. The sales and events team with vendors toward making every event as green as possible. Vendors are offered a post-event sustainability report outlining diversion data, compost data, and best practices observed during the event. Further, the team tours sustainability partner facilities to observe first-hand how their efforts are working. The committee recently toured Hammond Farms in East Lansing, which composts more than 66 tons of unused food from Huntington Place events annually. WHAT EXAMPLES DOES HUNTINGTON PLACE HAVE IN PLACE? According to Turnbore, Huntington Place’s four biggest priorities are waste diversion, energy savings, food waste management, and employee education. Here are just some of the green initiatives currently in place: Sitting off the Detroit River, Huntington Place HVAC system pumps gray water from the Detroit River through chillers that then send the cool water to various air handlers, providing cooling to zoned areas in the center. This system uses considerably less electricity than conventional air conditioning units. The Huntington Place $279 million facility upgrade incorporates numerous green building components including low-flow restroom and kitchen equipment, energy-efficient HVAC equipment, and a living green roof. Centerplate, the Huntington Place food and beverage provider collects prepared food that has not been served for pick up by Forgotten Harvest, a local nonprofit that delivers the food to pantries, soup kitchens, and shelters throughout Southeastern Michigan. Materials left by events are donated to local agencies for reuse and upcycling. Exhibit halls are equipped with induction lighting that uses 50% less electricity. All main hall lighting and heat/cool settings are computer programmed and managed. Escalators in the building are energy efficient, Kone EcoMod units. Escalators operate based on occupancy and
