New Process Fiber, a thermoplastics manufacturer serving a variety of industrial markets, faced steadily rising energy costs tied to its electricity-intensive operations. To identify opportunities for savings and system improvements, the company partnered with the Industrial Training and Assessment Center (ITAC) program. In April 2011, a team from the University of Delaware ITAC conducted a no-cost, on-site assessment of the facility.
The ITAC team examined major energy users such as compressed air systems, motor-driven equipment, and facility lighting. Key recommendations included lowering compressed air system pressure, fixing leaks, upgrading to high-efficiency lighting, and implementing equipment scheduling to reduce unnecessary run time. These measures were tailored to the plant’s operations, offering both immediate low-cost improvements and longer-term upgrades.
By implementing seven of the recommended measures, New Process Fiber realized annual savings of more than $22,000, cutting electricity use by nearly 200,000 kWh each year. The projects paid back quickly, with several implemented in less than two years. In addition to lowering operating costs, the improvements strengthened system reliability and helped the company align with emerging sustainability goals.
This case illustrates that even modest-sized manufacturers can achieve substantial benefits through an ITAC assessment. For New Process Fiber, small operational changes translated into meaningful energy savings and positioned the company as a leader in efficient thermoplastics manufacturing.