Innovation Will Streamline CFL Manufacturing Process

Energy efficient lighting innovator TCP, Inc. is revolutionizing the compact fluorescent lighting market with the introduction of the first automated machine to bend compact fluorescent light bulbs (CFLs) into their familiar spring shape. This innovation will streamline the CFL manufacturing process, allowing the company to dramatically increase capacity to meet the growing global demand for energy efficient lighting.

TCP currently manufactures 1.4 million CFLs per day, accounting for a majority of the CFLs on the U.S. market and an annual reduction of 118 million pounds of carbon dioxide emissions. Each automated bending machine can produce an additional 5,500 CFLs per day, which is nearly five times as many as produced by the company's manual bending process.

"As more countries move to phase out incandescent light bulbs, the question becomes 'will there be enough CFLs to supply the market?'," said Ellis Yan, CEO, TCP, Inc. "We have made a significant investment in automated technology and are confident that this development will allow us to keep up with increased consumer demand. CFL capacity will not be an issue."

TCP is the only lighting company to control all aspects of the manufacturing process, ensuring a higher quality and longer lasting product. Unlike other manufacturers, TCP owns its glass and circuit board factories. The company produces lead free glass to improve the lumen maintenance over the life of the bulb and also manufactures lead-free solders used in the ballasts of its CFLs.

As another step toward making CFLs the best lighting choice for the environment, TCP is the first manufacturer to use 100% amalgam, a solid form of mercury and other elements. This guarantees that only the minimum amount of mercury is placed in the CFL. Other manufacturers use liquid mercury, which is less expensive and more difficult to accurately dose.

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