Smooth Ambler Spirits, a renowned distilled spirits producer located in Maxwelton, West Virginia, sought to enhance energy efficiency and reduce costs in its operations. Distilleries are highly energy-intensive, relying on electricity, natural gas, and process heat, making them excellent candidates for efficiency improvements. In partnership with the Industrial Training and Assessment Center (ITAC) at West Virginia University, the company received a no-cost, on-site energy assessment focused on uncovering practical opportunities to reduce consumption and boost competitiveness.
The WVU IAC team conducted a detailed review of the facility’s major systems, including boilers, chillers, lighting, and process equipment. Ten key recommendations were developed, such as recovering CO₂ from the fermentation process, installing evaporators to minimize effluent waste, adding a variable speed drive to the chiller compressor, improving boiler air-to-fuel ratios, and upgrading lighting with LEDs and occupancy sensors. Additional measures included preheating combustion air, insulating hot water systems, and optimizing compressor controls. Together, these strategies addressed both energy efficiency and process reliability.
If fully implemented, the recommendations would reduce annual energy use by 104,878 kWh of electricity and 1,830 MMBtu of natural gas, resulting in $59,174 in annual cost savings. The projects also carry an average payback period of just 30 months and will cut 436,473 pounds of CO₂ emissions each year. Beyond energy and cost savings, the assessment encouraged the adoption of preventative maintenance practices, such as vibration analysis on motors, further extending equipment life and efficiency.
This case demonstrates how ITAC assessments can deliver substantial financial and environmental benefits even in specialized industries like distilled spirits manufacturing. Smooth Ambler’s experience shows that energy assessments not only identify cost savings but also support sustainable growth and competitiveness.