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.

## Verifying Compressed Air and Gas Safety and Quality in Medical Applications

Compressed air and gases are vital to numerous healthcare facility operations. Commonly used for breathing, sedation, and the operation of medical instruments, healthcare facilities must rely on these utilities for lifesaving and therapeutic benefits. The quality of the air and gas produced by the facility’s compressed air systems is paramount to their efficacy in promoting positive outcomes for patients.

## Weston Foods’ Achieves ENERGY STAR® Certification with Commitment to Sustainability

As a leading North American bakery company Weston Foods ensures its numerous facilities productively and cost-effectively produce high-quality baked goods. But it doesn’t stop there. It goes the extra mile to optimize and manage its utilities to conserve energy and protect the environment.

## How to Keep Reverse Pulse Dust Collectors Operating Efficiently and Reliably

Reverse pulse type dust collectors often represent a challenge to compressed air energy efficiency, and sometimes throw a wrench into the works by causing huge air pressure fluctuations, high transient flows and just plain large leaks. This article discusses this type of dust collector, often installed in food processing plants, and gives some real-life examples of problematic installations. Some suggested measures are mentioned to ensure your dust collectors keep running in a trouble-free manner.

In a strategic approach to improving its management of compressed air, the company initiated an upgrade of its compressed air system at its Midway plant. In so doing, SumiRiko Tennessee saves 2.1 million kWh and \$100,000 in energy costs per year at the plant. Additionally, lower energy use resulted in the reduction in CO2 of 800 tons per year. With a utility rebate, the project paid for itself within two years. ## Automaker Saves$600,000 Yearly In Energy Costs & Improves Compressed Air System Reliability

The project, which also involved the addition of a booster air compressor and receiver tank – along with the installation of an important pressure control valve – gives the automaker the ability to run fewer centrifugal air compressors during peak production. In so doing, the plant saves nearly 6.1 million kWh and more than \$600,000 per year in energy costs. The project also qualified for a \$369,374 rebate from the local utility, resulting in a six-month project payback – all while improving system reliability.

## Outsourcing Compressed Air Gives GKN Sintered Metals Peace of Mind

With an eye toward strengthening its competitive edge, GKN opted for a new approach for the compressed air it uses to power metal molding machines in addition to a variety of other applications at its manufacturing facility. After careful analysis and planning with the Total Equipment Company located in Coraopolis, Pennsylvania, GKN opted to move beyond its aging compressed air system – and instead – outsource compressed air as a utility. Doing so allowed it to free up valuable floor space, while also achieving peace of mind since it can now count on a fixed cost for a reliable compressed air supply for years to come.

## Profile: Case Controls and Centrifugal Air Compressor Management

Often, multiple centrifugal air compressors are set up to simply react to air demand, which requires the system to not only meet the new demand, but also make up for air depleted in the main header. This typically results in too much supply, which results in bypassing the air to atmosphere. The result is wasted energy use.

## Lessons Learned in Rebar Steel Mill Compressed Air System Project

The steel mill in this article is a rolling “minimill,” a facility that melts scrap recycled steel and produces rebar for the construction industry. It fits in SIC code 3310. There are many plants like this all over the world, providing an environmentally sound service and product for their local community. They recycle waste steel from local sources and support local infrastructure projects with rebar, using electricity generated locally.

## A Case for KPI Measurement in Compressed Air Management

All industrial facilities use some form of compressed air, and in most, the air compressors consume a significant amount of the total energy bill. A facility with a good energy management system is likely to identify their compressed air system as a significant energy user (SEU). If the facility were using an energy management standard, such as ISO 50001, they would be required to assess and track the energy consumption of all their SEU’s. In the case of the metal processing facility, they were measuring the output of more than 250 devices within the plant, including building heaters, RTU’s, dust collectors, and also tracking the consumption of their electricity, natural gas and water.

## Reducing Brewing Costs with Onsite Nitrogen Generation

Brewing is normally broken down into four stages-malting, mashing, boiling and fermenting. The complex chemical processes begin with a few simple ingredients - hops, grain, yeast and water. Recently there have been technological advancements to safeguard that these steps are attained accurately, efficiently and with cost-savings. One particular improvement is the use of nitrogen during the brewing process. The addition of an onsite nitrogen generator allows brewers to reduce their nitrogen costs, eliminate downtime, and reduce safety risks related to bulk gas cylinder delivery and changeouts.

## Auto

“I’ll say this politely. At the end of the day, we shouldn’t have to worry about compressed air,

## Bulk

For Imerys S.A. there’s little question about the importance of managing dust collection systems it

## Food

Sustainability is a high priority for today’s consumer packaged goods (CPG) companies. Driven by

## Medical

The air is delivered through a distribution piping system that ends with a medical air outlet

## Metals

Since completion of the system upgrade in the fall of 2020, PC Forge is on track to save an average

## Paper

The facility has a compressed air system consisting of four, 200-horsepower (hp) two-stage water-

## Plastics

Berry Global was established in 1967 as a small hometown company, based in Evansville, Indiana.

## Power

A newly constructed ethanol plant experienced control gap issues shortly after comissioning.  This

## Printing

The Trinity Mirror Group print works on Oldham is one of the UK’s largest newspaper printers. The