Multi-wall Packaging, a manufacturer of paper and packaging products, operated an energy-intensive facility where electricity and natural gas accounted for a significant portion of operating expenses. To reduce costs and enhance efficiency, the company engaged with the Industrial Training and Assessment Center (ITAC) program. In June 2006, a team from Texas A&M University’s ITAC performed a no-cost, on-site assessment at the facility.
The ITAC team examined core systems including compressed air, motor drives, and production line operations. One of the standout findings was a recommendation to improve storage and material handling efficiency, which reduced wasted motion and unnecessary energy consumption. Additional recommendations included upgrading to high-efficiency motors, repairing compressed air leaks, and optimizing equipment scheduling to minimize idle energy use.
The assessment revealed opportunities for the company to save over $100,000 annually in energy costs, with payback periods ranging from a few months to under two years. Implementing these measures not only lowered energy bills but also improved workflow, boosted system reliability, and extended equipment life.
This case shows how ITAC assessments uncover savings beyond traditional upgrades. By focusing on process efficiency in addition to technical improvements, Multi-wall Packaging strengthened its competitiveness and reduced its environmental footprint.