GF resource conservation projects reduce the company’s environmental impact

By John Compani
Senior Member of the Technical Staff for Corporate Environmental, Health, and Safety and Sustainability, GlobalFoundries

This week GlobalFoundries (GF) is celebrating our second annual Earth Week, in honor of Earth Day and our collective responsibility of being a good steward of our planet and its resources. Our theme for Earth Week is: “ONEGF, One Planet, Protect it Together.”

As Dr. Thomas Caulfield, president and CEO of GF, said earlier this week when announcing our new goals of achieving net zero emissions and carbon-neutral power by 2050:

“Climate change is a universal concern for every nation, company and person on this planet, and there are no do-overs when it comes to global warming. It is incumbent upon all of us to take meaningful action to fight against this risk.”

GF has a longstanding commitment and proven track record of sustainable operations and minimizing our impact on the environment. Below are examples of GF’s commitment in action, across the key areas of greenhouse gas (GHG) emissions and electricity consumption. Watch for an article later this week on other key resource conservation efforts in the areas of water use, hazardous waste management and chemical usage.

Greenhouse Gas Emissions

Earlier this week, GF doubled down on its commitment to sustainability by announcing exciting new goals of achieving net-zero greenhouse gas (GHG) emissions and 100% carbon-neutral power by 2050. This work builds upon GF’s Journey to Zero Carbon pledge to reduce our GHG emissions by 25% from 2020 to 2030.

We are on track to meet this 25% reduction goal by 2030, thanks to strong leadership and our innovative global team applying a variety of approaches and investments tailored to GF’s unique global manufacturing footprint. Our efforts are paying off, with GF emitting 27% less GHG per wafer¹ in 2023 than it did in 2020. The combined reoccurring annual benefits of projects completed in 2023 alone resulted in approximately 125,000 MTCO2e of GHG reductions, that’s roughly equivalent to the emissions from driving a car around the earth 1,500 times²!

Below are a few examples of the many exciting projects GF’s team completed in 2023 to help reduce our GHG emissions:

• In Vermont, the installation of point-of-use abatement devices on specific tools resulted in annual GHG emission reductions of 2,800 MTCO2e, and the qualification and use of alternative heat transfer fluids in some etch tools will reduce annual GHG emissions by 6,600 MTCO2e and provide approximately $60,000 per year in material savings.

• In New York, the qualification and use of alternative heat transfer fluids in a group of chemical vapor deposition equipment will result in approximately $185,000 in material savings and the elimination of 35,000 MTCO2e in greenhouse gas emissions per year.

• In Singapore, a multi-year project continued to upgrade specific tools with a more efficient chamber-cleaning process resulting in a GHG emission reduction of 78,000 MTCO2e per year.

Additionally, earlier this year GF and Keppel announced a multi-year power purchase agreement to provide electricity at GF’s Singapore site. By using power from Keppel’s new advanced power plant scheduled for completion in 2026, it is expected that GF will be able to reduce emissions from its Singapore site by more than 10% – or up to 70,000 tons of CO2 emissions – per year. Click here to read more.

Electricity Use

Semiconductor manufacturing is an energy-intensive process. Not only do electricity conservation projects save money, but they can also reduce the GHG emissions generated as a byproduct of producing that electricity.

In 2023, GF’s sustainability and efficiency efforts produced an annual savings of more than 23.5 million kilowatt-hours (kWh) of electricity – enough to power approximately 2,200 U.S. households for a year³. This resulted in significant savings in operational costs as well as a reduction in indirect GHG emissions associated with the purchased electricity.

With the completion of power-saving projects in 2023, GF on average used 19% less electricity to produce a wafer¹ than it did in 2020. Examples of these projects include:

• In Dresden, Germany, two additional heat exchangers were put into operation to support process chilled water systems, resulting in a savings of approximately 170,000 kWh per year and nearly 2,400,000 kWh per year in LED lighting upgrades were made to the facility.

• In Singapore, strategically removed heat tracing on a group of etch tools resulting in energy savings of 733,000 kWh per year.

• In New York, nearly 800,000 kWh in LED lighting upgrades were completed in the cleanroom, and new improvements to temperature controls for areas of the subfab and cleanroom resulted in over 554,000 kWh per year of electricity savings.

Also, earlier this year, GF supply partner Air Liquide announced an investment of over 50 million euros to build a new plant in Singapore and revamp its existing facilities in Malta, New York, to supply high purity nitrogen to GF. These Air Liquide projects are expected to enable GF to benefit from higher energy efficiencies. Read more about it here.

John Compani is a Senior Member of the Technical Staff with GF’s Corporate EHS & Sustainability Team. He is based in Malta, New York, with focus on GF’s Environmental Performance, Resource Conservation and Sustainability efforts.

¹ “per wafer” is an approximation; the technical measurement is “per production output” which takes into consideration the size of semiconductor wafers (200mm or 300mm) and complexity of the product (number of mask layers) when calculating GHG emissions or electricity use per wafer.

² GHG Protocol Average gasoline car emission factor 2 kg CO2e/vehicle-km [link]

³ Using the U.S. Energy Information Administration’s estimate that the average U.S. household consumes about 10,500 kilowatt-hours (kWh) of electricity per year. [link]

Payne’s perspective on showcasing beauty, complexity and the future in semiconductor manufacturing 

In late 2022 GlobalFoundries (GF) invited Chris Payne, an acclaimed photographer with a specialization in architectural and industrial photography, to our Malta, New York, facility for a behind-the-scenes glimpse into the world of semiconductor manufacturing. Over the course of six days, he captured dozens of images, showcasing the intricate processes of GF’s cleanroom, sub-fab and other key areas. Several of these striking images are featured in Payne’s recent book, ‘Made in America’ and are now proudly displayed in the ‘Semiconductors Unveiled’ gallery at our headquarters. We recently caught up with Chris to ask him about his creative journey at GF and how his photography bridges art with the cutting-edge world of semiconductor technology. 

Q: Thanks so much for connecting, Chris. Your latest book ‘Made in America’ includes a section on semiconductor manufacturing. What inspired this focus? 

A: In my book I wanted to tell a comprehensive story about manufacturing, drawing a narrative arc from older, more traditional processes to newer, more technologically advanced ones, like the making of semiconductor chips. Being able to photograph GlobalFoundries was like having the final chapter written and made it easier to assemble the rest of the book. 

Q: How did your perception of the company evolve throughout your photographic journey? 

A: Walking into the giant cleanroom for the first time was overwhelming and I realized that I would need help from GF to plan and make the pictures. I couldn’t have asked for a better partner; the shoots felt like a creative collaboration where we all shared a common goal. This level of cooperation and generosity is rare in an age when tech companies are wary of opening their doors to photographers. 

Q: Before visiting GF, what were your main objectives or hopes for the photography project? How did these goals shape your approach? 

A: My main objective was to make a series of compelling pictures that strike a balance between beauty and information, that pull back the curtain on the chipmaking process while also being aesthetically pleasing. I tried to avoid the generic views we’ve seen before of cleanrooms with workers in white bunny suits. For my pictures I knew I needed to dig deeper, so we spent many hours exploring the fab to come up with new and interesting ideas. 

Q: Can you describe the process and any unexpected hurdles you encountered photographing in GF’s semiconductor fab? 

A: As a photographer, I’m accustomed to an immersive, hands-on approach, but this wasn’t possible at GF since I was suited from head to toe in protective gear. Every piece of my equipment had to be wiped down before entering the fab, and we had to budget extra time to get around such a vast and labyrinthine site. That said, I enjoyed the luxury of widespread access and had all the help I needed from the GF team, so things couldn’t have gone smoother. 

Q: Was there anything about GF or semiconductor manufacturing that surprised or intrigued you during your visit? 

A: What I found most intriguing was the contrast in scale between the miniscule size of the chips and the immense size of the factory. I can’t think of another product or process where this relationship is so disproportionate. I’ve seen cleanrooms before, but I had no idea how much infrastructure is required to make it all work. 

Q: Of all the images you captured at GF, which one do you find the most aesthetically striking, and which is your personal favorite?  

A: If I had to choose one picture, it would be the view looking up at the FOUPs (Front Opening Unified Pods) running along the AMHS (Automated Material Handling System). I remember when I first saw the FOUPs zipping overhead I felt as if I had walked into the future. For this picture we were able to choreograph the FOUPs by slowing them down and rerouting them to create a bustling intersection. 

Another personal favorite is the image of [GF senior engineer] Lydia inspecting the wafer sorter. Here I was able to place my camera inside the sorter and have Lydia peer inside to create a dramatic, intimate scene. Even though the fab is mostly automated, humans must keep a watchful eye to ensure that everything runs smoothly.  

Q: Semiconductor manufacturing is rarely seen as a subject of fine art. How did you approach revealing the beauty in this technical and industrial process? 

A: It’s impossible to photograph semiconductor chips being made, since the process is inaccessible and hidden from view, but I knew there had to be a way to convey its complexity. I recall my disappointment when we toured the sub fab because it seemed generic, like any other mechanical space. Then I looked up and saw a maze of pipes and tubes feeding the cleanroom, revealing the fab as one giant interconnected machine. It was the perfect balance of order and chaos, yet still ambiguous enough to inspire imagination and awe, and shows that beauty can be found in the most unexpected of places.   

Q: How do you think your work, particularly in semiconductor manufacturing, influences public perception or understanding of this industry? 

A: I’d like to think that I’m doing important work, documenting one of the most essential technologies of our time. If my pictures make people pause to appreciate what it takes to sustain our modern, digital way of life, then that’s a bonus. But even if no one notices or cares, I’m still grateful for having seen this incredible place, and look forward to future collaborations with GlobalFoundries! 

GF earns top score in the Human Rights Campaign Foundation’s 2023-24 Corporate Equality Index 

By Emma Cheer  
Director, Diversity, Equity, Inclusion and Belonging at GlobalFoundries 

GlobalFoundries (GF) is proud to announce we have earned a top score in the Human Rights Campaign (HRC) Foundation’s 2023-2024 Corporate Equality Index (CEI). This is a big deal – it’s the leading survey and report measuring lesbian, gay, bisexual, transgender and queer employee (LGBTQ+) workplace equality, and our score reflects GF’s dedication to an inclusive culture where everyone, regardless of their identity, feels valued and respected. 

GF received a perfect score of 100 for the CEI. Much more than just an accolade for GF, this score represents our deep-rooted belief that a diverse and inclusive workforce improves business outcomes by fostering innovation, improving employee engagement and retention, attracting talent, and increasing productivity. 

GF celebrated this news at many of its U.S. locations. 

“Working for a company that shares my core values was a key differentiator when I chose to join GF,” said Jean Trewhella, GF’s director of post fab engineering and executive sponsor of the company’s Pride@GF employee resource group. “Gaining the HRC CEI 100 score is a visible and bold indicator that GF continues to grow along these core values of diversity, equity and inclusion, making GF a great place to work for employees and the obvious choice for new hires!” 

The 2023-2024 CEI included 1,384 participating organizations advocating for specific gender identity non-discrimination protections. Covering 21 million employees worldwide, these protections are crucial and we are honored to be part of this progressive change. 

In the words of RaShawn “Shawnie” Hawkins, HRC’s senior director of workplace equality: “Our goal at the Human Rights Campaign Foundation is to work in a spirit of partnership with companies, providing educational resources and leading benchmarking, and collaborating on ways for businesses to support the LGBTQ+ community at a time when we face unprecedented legislative attacks, heightened anti-LGBTQ+ rhetoric and physical violence. The CEI is an ever-evolving tool – a blueprint that companies can use to show up more effectively in supporting their LGBTQ+ employees and their families.” 

Click here to learn more about diversity and inclusion at GF and click here for more information on the HRC CEI 2023-2024. 

About Pride@GF 

Pride@GF is a GF employee resource group that is dedicated to providing an inclusive environment for members of the LGBTQ+ community and their allies, empowering employees to bring their full selves to work, and informing and guiding GF to create a culture of inclusion.