Industrial Utility Efficiency    

Industries

Products manufactured at the 100,000-square-foot plant in Kentucky include columns, I-shafts, covers, keylocks, and other dressings, along with shifter applications, such as straight, tap-up/tap-down and gated shifters. In all, the facility supplies automakers with products used in more than 100 different applications, all of which are designed keep vehicles operating safely, smoothly and reliably.

Auto

The Ford Motor Company Kentucky Truck Plant (KTP) not only manufactures upscale SUVs and pickup trucks painted in wide variety of stellar, high-quality colors and finishes –  it does so cost-effectively by conserving annual compressed air energy of approximately 9.2 GWh thanks to a major overhaul of the plant’s compressed air system.

Bulk

For Imerys S.A. there’s little question about the importance of managing dust collection systems it uses to control and reduce harmful particulates in its worldwide minerals processing facilities. And now there’s zero doubt about the tremendous energy savings it stands to save by reducing the amount of compressed air needed for these same dust collectors.

Food

In 2021, Compressed Air Best Practices® Magazine interviewed members of the Molson Coors Canada team, at their Toronto Brewery, to gain an understanding of the work being done to improve energy efficiency. The team members interviewed were Doug Dittburner (Chief Engineer), Antonio Mayne (Utilities Optimization Engineer) and Khalil Daniel (Engineering Intern).

Medical

The air is delivered through a distribution piping system that ends with a medical air outlet within the room. Outlet requirements per room are governed by American Institute of America (AIA) Guidelines for Design and Construction of Hospitals and Healthcare Facilities. Equipment is plugged into the medical air outlet to treat the patient. Many studies have been done determining the load required for medical air compressors. The sizing can be calculated using several methods. 

Metals

Manufacturers familiar with the U.S. Environmental Protection Agency (EPA) ENERGY STAR® Energy Treasure Hunts initiative know it’s a great way to save energy and natural resources – as long as it’s done right – which is why some are turning to perhaps their best asset to achieve success: their unionized workforce.

Paper

The facility has a compressed air system consisting of four, 200-horsepower (hp) two-stage water-cooled lubricant-free reciprocating air compressors. The air compressors are controlled individually with local pressure switch controls connected to a common pressure sensing point. These air compressors have been operating since the mid-1960s and are very difficult and expensive to maintain because parts are scarce and service companies with experience servicing this type of air compressor are difficult to find.

Pharmaceutical

This article is intended to show the relationships between risks and specifications, opportunities and responsibility in validation, and in particular, the use of modern and calibrated measurement technology in the sample chain.

Plastics

Berry Global was established in 1967 as a small hometown company, based in Evansville, Indiana. Today it is still headquartered in Evansville but has grown to 48,000+ global employees and more than 295 locations. Generating $12.6 billion in 2019 pro forma net sales, Berry Global creates innovative packaging and protection solutions.

Power

A newly constructed ethanol plant experienced control gap issues shortly after comissioning.  This article discusses the cause of the issue and how the problem was solved.

Printing

The Trinity Mirror Group print works on Oldham is one of the UK’s largest newspaper printers. The nine presses in the facility produce around 1million papers every day, including the Independent, the Daily Mirror and a range of local, regional and sports titles. Printing on this scale does not come cheap in energy terms, however. The plant’s annual electricity bill is in the order of £1.5millon. With energy prices on the rise, and a strong desire to improve environmental performance and reduce its carbon footprint, the plant’s management has recently embarked on a project to cut energy use substantially.

Transit

When the New York City Transit Authority (NYCT) set out to comply with local regulations calling for reductions in energy usage, it leveraged new air compressors for use in transit bus maintenance and repair – and took things to another level by recovering air compressor waste heat to provide hot potable water for the bus depot. The air compressor and heat recovery system, installed in spring 2017, is on its way to helping NYCT achieve the best energy savings possible.

Wastewater

The plant upgrades, in combination with a progressive management strategy, allows the plant to consume less energy and reduce its reliance on outside contractors for biosolids removal, resulting in total operational savings of approximately $60,000 per year.  The plant is also positioned to efficiently manage the area’s wastewater for decades to come.
Berry Global was established in 1967 as a small hometown company, based in Evansville, Indiana. Today it is still headquartered in Evansville but has grown to 48,000+ global employees and more than 295 locations. Generating $12.6 billion in 2019 pro forma net sales, Berry Global creates innovative packaging and protection solutions.
Danone today announced, in December 2020, that it has been highlighted for the second year in a row as a world environmental leader by the international non-profit organization CDP, whose disclosure and scoring system is recognized as the gold standard of corporate environmental transparency.
In 2021, Compressed Air Best Practices® Magazine interviewed members of the Molson Coors Canada team, at their Toronto Brewery, to gain an understanding of the work being done to improve energy efficiency. The team members interviewed were Doug Dittburner (Chief Engineer), Antonio Mayne (Utilities Optimization Engineer) and Khalil Daniel (Engineering Intern).
When compressed air is essential to the production of up to one million plastic containers per day there’s little room for error. That’s why Schoeneck Containers, Inc. (SCI) leaves no stone unturned to ensure its compressed air systems run smoothly at all times and without fail at its bustling facilities in Wisconsin.
Micro-aerosolized droplets are how many members of the microbial world become cross-contaminants via the air mode of transmission.  Food borne viral pathogen Hepatitis A and the ubiquitous Norwalk are very often transported via micro- aerosols. It is well known that many viral or bacterial pathogens or spoilers are transmitted via respiratory bursts [coughs/ sneezes] from people or air handling system, condensate, and splash back from floors. Strict cGMPs  can limit  and control transmission in terms of personal & environmental  hygiene.
There are a tremendous variety of unique and creative ways people in the food industry have overcome their need for compressed air blowoffs used for cleaning, drying, cooling, conveying and overall processing. You may have seen some of them yourself. It is not uncommon to view open copper tubes, pipes with a crushed end, plugs or caps with holes drilled into them, modular flex coolant lines or nozzles designed for liquid application but blowing air.
In February 2021, Compressed Air Best Practices® Magazine interviewed members of the Intertape Polymer Group Inc. (IPG) Sustainability Pillars team to gain an understanding of the work being done to improve energy efficiency. The team members interviewed were Michael Jones (Director of Corporate Energy), Michael Deitering (Senior Project Engineer), Jarrod Knapp (Maintenance Manager) and Mark Secord (Engineering Group Leader).  
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.
The Wonderful Pistachios and Almonds campus in Lost Hills, California is a manufacturing facility that processes and packages pistachios and almonds for the consumer market. Food processing requires extensive use of compressed air to control multiple applications ranging from actuators, valves, optical sorters, packaging equipment and plant maintenance operations. The campus has its peak season during harvest in late August/early September, but processing and packaging operations take place year-round.
For decades, a major meat processor and packaging operation in Northern England did what many growing companies do when more compressed air is needed to meet demand: added another air compressor and then another air compressor and so on. Yet the company decided the strategy of adding equipment had run its course, especially given a positive outlook for continued growth and the need to resolve nagging issues with system downtime and compressed air quality.