SCS BT Squared

Heat Recovery

A glass manufacturer suspected that excess process heat could be re-used in the facility instead of being discharged to the atmosphere. They wanted engineering assistance to assess the options and cost-saving opportunities. BT Squared evaluated the quality and quantity of heat from two primary heat sources (glass quenching and compressed air drying) and potential uses for the waste heat (glass washing and HVAC makeup air). The feasibility study identified five potential solutions, including conceptual design drawings, estimated costs, and potential annual savings of $22,000. Once successfully implemented at this plant, the manufacturer plans to share the design and results with its other facilities.

Energy Assessment

This industrial equipment manufacturer wanted to improve energy efficiency and improve their bottom line. BT Squared completed an energy assessment that identified $55,000 worth of primary energy savings opportunities in HVAC, lighting, compressed air, and controls, representing 19% of total energy consumption. One measure had a $5,000 savings with no implementation cost by changing the existing control strategy. In addition to the primary energy saving measures, we identified seven smaller areas for improvement and provided an “energy dashboard” to help the company track pertinent energy metrics and greenhouse gas reductions over time.

Greenhouse Gas Emission (GHG) Management

Copps Industries, an epoxy and resin formulator with a strong commitment to sustainability, was asked by a European customer to inventory their GHG emissions and prepare a management and reduction plan. Using USEPA guidelines, BT Squared quantified Copps’ energy usage, helped define their GHG emissions for a baseline year, and established a plan for continuous measurements/improvements into the future. We also provided an “energy dashboard” to help Copps track pertinent energy metrics over time. The Management Plan identified specific energy saving projects (e.g., Energy Management System, building envelope, compressed air) that would allow Copps additional reductions toward their GHG goals.

Lean & Clean Assessment

A family-owned cheese maker wanted to drive additional efficiency into their processes, energy consumption, and water usage for the main product produced. Working closely with multi-disciplinary facility personnel, BT Squared and the Wisconsin Manufacturing Extension Partnership (WMEP) measured process-related details and developed a Value Stream Map (VSM). The VSM took into account value-added time (labor), energy, water, chemicals, wastes, and other cost-driven elements to help optimize each step in the production process. The project deliverable was a prioritized list of projects designed to maximize sustainability while improving the bottom line. The energy projects with the quickest paybacks included insulating chiller/refrigerant surfaces, installing occupancy sensors for lighting, and upgrading the boiler system. The client is most excited about an opportunity to enhance their wastewater treatment efficiency using a renewable energy source, which affects multiple process elements and improves their ability to expand operations.

Compressed Air

This food can manufacturer wanted to evaluate their use of compressed air. Compressed air is often considered a fourth utility (following electricity, natural gas, and water) and its cost is often hidden in overhead. BT Squared conducted an energy assessment at this manufacturer and identified significant savings opportunities with how compressed air is used. BT Squared helped evaluate options in how compressed air is used in their can production lines. Instead of high-pressure compressed air, the company is installing a lower-pressure blower. The lower-pressure air meets the facility’s needs for metal-sheet separation, cooling, and removing particulates/dust, while consuming less electricity than high-pressure compressed air. The project also reduces the load on the compressors, potentially avoiding the purchase of additional compressors to meet future demand. With funding assistance, including state energy incentives, the simple payback is less than one year. BT Squared also used an ultrasonic leak detector to complete a compressed air audit that identified 77 leaks. Once the compressed air system repairs are complete, the company estimates that they will save an additional $57,000 annually.

Hazardous Waste Minimization

A battery manufacturer was spending approximately $13,000 per year on solvent purchases, transportation, and disposal of the spent solvent. BT Squared evaluated alternatives, prepared an assessment report that recommended a distillation unit to reclaim the solvent, and solicited vendor bids for the system. The estimated simple payback is approximately 1.9 years. In addition, the distillation system will reduce the facility’s carbon footprint by 27,000 pounds per year, and hazardous waste generation by 11,000 pounds per year. These material reductions will show important progress to customers who are evaluating the company’s sustainability program.

Energy Sales Tax Exemption

A concrete manufacturer was not taking full advantage of the available sales and use tax exemptions for energy consumed in manufacturing tangible personal property. By analyzing historic energy data from electricity and natural gas meters, BT Squared calculated the percent of energy that is exempt from sales tax, helped the manufacturer obtain a refund for four years of state and county taxes paid to the Department of Revenue (DOR), and drafted the utility company forms to avoid paying these taxes in the future. After proving that the process was profitable for one facility,
BT Squared reviewed data from other representative locations to expand the cost savings and document the process for potential DOR audits. The tax refunds of $29,000 far exceed the project cost for an immediate return on investment, and the company now realizes additional savings of nearly $14,000 per year. In addition, the detailed electrical analysis confirmed that motors are the largest source of the company’s energy use, which helped the company prioritize some low-cost efficiency projects to reduce consumption and greenhouse gas emissions.