Industrial Utility Efficiency

End Uses

In this article, we will provide detail on the characteristics of the baseline system and then share the energy-saving work identified in two projects. These two projects represent work which can be performed by the maintenance teams in every plant. These are also project opportunities we find in almost every plant we visit. The two projects are to (1) repair/replace condensate drains wasting compressed air and (2) to perform a compressed air leak survey.

SumiRiko Tennessee Saves Energy & Boosts Sustainability with Compressed Air System Upgrade

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.

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.

Capital & Maintenance Cost Avoidance When Metal Grinding Loads Rise

Plant personnel had experienced ongoing problems with its process grinder performance due to unstable compressed air pressure. This created potential problems in terms of product quality. Grinders do not work properly without the proper pressure. Additionally, plant staff wanted to address these concerns, prior to a proposed 30% increase in production, and suggested raising the header pressure from the current operating pressure of 98 psig to 125 psig. The thought behind this was if the pressure from the header to the grinder process was dropping to 63 psig, then raising the pressure to the process would give the grinders enough pressure to work through higher peak production times.  

Bearing Cooling: A Common Misapplication of Compressed Air and How to Fix It

One observation I’ve made from 30 years of working with compressed air systems is to never underestimate the ingenuity of plant personnel when it comes to misapplying compressed air. We see something new in virtually every plant we visit, but one of the more common problems we encounter involves the use of expensive air for bearing cooling. 

Reviewing Dust Collectors and Nitrogen in a Food Manufacturing Plant

This major food manufacturing plant in the Midwest uses compressed air and onsite nitrogen generation to operate multiple snack production and packaging lines. The plant spends an estimated \$430,344 annually on energy to operate its compressed air system based on an average rate of 4.5 cents per kWh.

Missed Demand-Side Opportunities Part 5 - Think Inside the Box to Achieve Savings with Cooling of Control Enclosures

In this ongoing column, we share insights into technologies that offer the opportunity to affordably and easily lower compressed air use and generate energy savings – all while achieving relatively quick payback. But finding these technologies on the production floor isn’t always easy or straightforward. In fact, there are many times when a technological solution is far less than obvious. Such is the case with cooling of control enclosures, which represent a significant area for high-energy savings with little upfront investment. Here is some out-of-the-box thinking…  check that… inside-the-box thinking… for optimizing control of enclosure cooling and coming out ahead.

Big Improvements at a Small Sawmill

Spruce Products Limited operates with five separate compressed air systems in their various buildings. A few years ago a sharp-eyed air compressor service representative noticed the screw compressors on site had less than optimal loading to operating hours ratios. Recognizing this was a problem, he suggested the company get in touch with their local power utility for a free compressed air scoping assessment. As a result, SPL has optimized two of their compressed air systems to-date, saving significant operating costs. One system is operating at 86% less energy consumption than previous levels.