Industrial Utility Efficiency    

Energy Manager

A major producer of cement and building materials, CalPortland’s energy management efforts have reduced the company’s overall energy intensity by 17.5% since 2003, avoiding $149 million in unnecessary energy costs – and over 3.3 million metric tons of Greenhouse Gas (GHG) emissions. In 2020, the company achieved what no other U.S. Industrial company has: It earned the ENERGY STAR® Partner of the Year Award for the 16th consecutive year.

Corporate Sustainability Programs

Tate & Lyle’s sustainability actions involve countless initiatives worldwide to minimize its environmental impact by reducing emissions and using water sustainably. Whether it’s the use of a low-pressure blower instead of a high-pressure compressed air system to save energy, or a $75 million natural gas-fired Combined Heat and Power (CHP) system to replace coal as a power source at its corn wet mill in Lafayette, Indiana, Tate & Lyle is on a mission to protect the planet.
Nissan North America operates on a massive scale. The company’s powertrain assembly plant in Decherd, Tennessee, alone encompasses 1.1 million square feet, and manufactures engines for 14 different vehicles. The facility also handles crankshaft forgings, cylinder block castings, and other machining applications. Over the course of one year, the powertrain plant churns out approximately 1.4 million engines, an equal number of crankshaft forgings, and 456,000 cylinder block castings.
Making cement is an energy-intensive process. In a cement plant, the electrical energy load can reach up to 25 MW, consuming 185 million kilowatt hours of electricity annually. In addition, the plant consumes a large amount of coal and natural gas. CalPortland is an enormous producer of cement, concrete, aggregates and asphalt. With 80 facilities spanning five states across the western U.S., one might logically assume that CalPortland consumes a lot of energy.
Compressed Air Best Practices® Magazine interviewed Michael Jones, Corporate Energy Team Leader, from Intertape Polymer Group (IPG). Intertape Polymer Group (IPG) is a manufacturer of tapes, films, woven fabrics, and complementary packaging systems for industrial and consumer use. The company operates 10 production plants and employs approximately 1,800 people. IPG has developed a robust energy management program by using ENERGY STAR energy management tools and actively participating in the ENERGY STAR partnership. IPG is receiving ENERGY STAR recognition for the growth of its energy program and leadership as a medium-sized manufacturer.
This is our first time receiving the award. We were hopeful we would receive it because we thought we achieved 23 out of the 23 attributes defined by the guidelines. Additionally, since the program was launched, GEM’s management practices have saved Corning more than $328 million in cumulative energy costs.  
The ENERGY STAR Awards are EPA’s highest honors for superior energy efficiency, and several award categories exist. EPA’s ENERGY STAR Industrial Partners could receive either Sustained Excellence or Partner of the Year in the Energy Management category. These awards go to organizations for adopting a continuous energy management strategy across the organization’s entire portfolio of buildings and plants and for communicating the value of ENERGY STAR and energy management broadly.
The story of Atlas Copco’s 140-year commitment to innovation. When thinking about innovation during the past century, the mind immediately wanders to consumer-facing brands that make products that are experienced by users – like a mobile computer and videophone that fits in our hands or the technology applications through which almost all modern business is conducted.
This facility operates one of the largest compressed air installations in industry, with 21 4000 hp process air and five 750 hp instrument air centrifugal compressors to support large-scale aerobic fermentation and related processes that require large volumes of oxygen.  
Compressed Air Best Practices interviewed Gregory Rhames, Asset Reliability Manager/Energy Manager at Verallia. As background, Verallia is the packaging division of Saint-Gobain. Verallia employs 15,500 people globally and makes about 25 billion glass bottles and jars each year. We employ 350 people at Madera where we produce about 1 million wine, champagne and sake bottles per day.
At our John Morrell, Smithfield Packing Company, Farmland Foods, and Murphy-Brown subsidiaries, we use an organized Environmental Management System to identify and manage every part of our operations that could have an effect on the environment. The focus is not only on compliance with applicable rules and regulations, but also on finding ways to continuously improve.
From sustainable agriculture and energy-efficient manufacturing processes to eco-friendly packaging initiatives, Heinz is proving that smart business is compatible with environmental stewardship. In factory after factory, a transformation is underway to improve sustainability measures and reduce operating costs by installing more efficient equipment, modernizing business processes and implementing new technologies.