A mid-sized manufacturing facility with significant utility costs engaged with the Industrial Training and Assessment Center (ITAC) program to uncover opportunities to reduce energy expenses and improve efficiency. In September 2019, the company welcomed an ITAC team on-site for a no-cost, comprehensive energy assessment. The goal was to identify practical measures to reduce reliance on natural gas and electricity, while maintaining productivity and product quality.
The assessment identified opportunities across both natural gas and electrical systems, with a focus on insulation upgrades, motor efficiency, and equipment scheduling improvements. One major recommendation was to enhance process insulation to cut unnecessary heat loss, while another focused on optimizing motor systems and operational timing to lower demand charges. The ITAC also advised adjustments in process scheduling to avoid simultaneous peak energy loads.
If implemented, the recommendations would result in savings of 284 MMBtu of natural gas and over 9,400 kWh of electricity annually. This translates to an estimated $32,000 in yearly cost savings, with payback periods ranging from just a few months to under two years. In addition to reducing operating costs, the measures would also lower greenhouse gas emissions and improve long-term system reliability.
This case highlights how even well-run mid-sized facilities can benefit from an ITAC assessment. With targeted improvements, the facility not only identified quick wins but also laid the foundation for long-term operational efficiency and sustainability.