Aluminum Recycling Facility Showcase Project
Alcoa has expanded its Barberton production plant to include a new 50,000 square foot recycling facility that uses a novel technology to reduce energy use by more than 30 percent relative to the method currently utilized. As a result of this project, Alcoa will use about half as much energy to produce and distribute recycled aluminum as it did before the plant was built.
Bentley Mills Boiler Control System Upgrades Showcase Project
Partner: Bentley Mills
Bentley Mills uses a large quantity of steam throughout their manufacturing process chain. In 2014, Bentley Mills began implementing a project to upgrade the control system for one of its largest natural gas fired boilers (Boiler #1) at its facility in the City of Industry, Los Angeles.
Cedar Rapids Heat Recovery Showcase Project
Partner: General Mills
General Mills is conducting a comprehensive heat recovery project at its Cedar Rapids, Iowa, plant that is expected to reduce energy usage by about 5%.
Compressed Air Efficiency Program Showcase Project
Partner: Johnson Controls, Inc.
The Continuous Improvement team at Johnson Controls’ Middletown, Delaware, manufacturing plant implemented a comprehensive program to reduce compressed air leaks and inefficiencies in the plant production process.
Compressed Air System Optimization Showcase Project
In March 2015 Darigold, America's fifth-largest dairy co-op, request a Better Plants In-Plant training (INPLT) to explore improvements and to educate its team, including personnel from other plants, on evaluating compressed air systems; this led to savings in the hundreds of thousands of dollars.
Eliminating Hydrogen Plant Natural Gas Compressors Showcase Project
Partner: Eastman Chemical
Eastman has hydrogen plants covering 118,000 square feet at its Kingsport, Tennessee facility that use high-pressure natural gas as a raw input to create hydrogen gas for polymer production.
Partner: Orange Water and Sewer Authority (OWASA)
The OWASA Mason Farm Wastewater Treatment Plant in Chapel Hill is nearly 86,000 square feet and services about 83,000 residents. Over the course of 2013 and 2014, OWASA renovated the aeration and mixing systems, saving an estimated 30 percent on electricity consumption.
Fan System Upgrade Showcase Project
Partner: Toyota Motor Engineering and Manufacturing North America
Spurred by a successful pilot project at its facility in West Virginia, Toyota implemented a comprehensive heating, ventilation, and air conditioning (HVAC) system upgrade at its Georgetown, Kentucky plant.
Four Seasons Produce — 50001 Ready Facility Showcase Project
Partner: Four Seasons Produce, Inc.
In June 2017, Four Seasons Produce, Inc., was recognized by DOE as the first U.S. 50001 Ready facility by implementing a continuous improvement-based energy management system at its 266,000-square foot fruit and vegetable refrigerated warehouse facility in Ephrata, Pennsylvania.
Partner: Volvo Group North America
Volvo Group NA, in the process of implementing an Energy Management System as part of its participation in the U.S. Department of Energy’s Superior Energy Performance program, identified building HVAC (heating, ventilation and air conditioning) as a Significant Energy Use at its Macungie, Pennsylvania plant.
HVAC Enthalpy Controls Upgrade Showcase Project
Partner: General Electric
In 2013, GE Gas Power Systems initiated a project to upgrade 100 rooftop heating, ventilation, and air conditioning (HVAC) units at its Greenville, South Carolina, gas turbine manufacturing facility.
Jamestown Engine Plant Showcase Project
Partner: Cummins, Inc.
Cummins is undertaking a deep energy retrofit project at its Jamestown Engine Plant (JEP) in Lakewood, New York, as part of its corporate-wide commitment to reduce energy intensity.
Laboratory Building 236 Ventilation Upgrade Showcase Project
3M improved the energy performance of one of its main laboratory buildings at 3M Center—the company’s corporate headquarters and primary research and development site—by converting the lab space ventilation system to variable air volume (VAV).
Partner: Celanese Corporation
In March 2015, Celanese successfully completed a $160 million boiler replacement project at this facility replacing coal-fired boilers with natural gas-fired boilers.
LED Project at New Regional Distribution Leased Location Showcase Project
Partner: Lennox International
As part of Lennox’s strategy for meeting the company’s energy and environment goals under its Sustainability 2.0 corporate initiative, Lennox evaluated its leased and owned distribution warehouses to identify opportunities to use high efficiency Light-Emitting Diode (LED) lighting.
Partner: Los Angeles Department of Water and Power
The Los Angeles Aqueduct Filtration Plant (LAAFP) was completed in 1986 and has a treatment capacity of up to 600 million gallons of water per day. In the mid-2000s, the Los Angeles Department of Water and Power (LADWP) began a comprehensive modernization of the LAAFP with a long-range program to upgrade and replace aging equipment.
Milford Compressed Air System Improvement Showcase Project
Partner: Saint-Gobain Corporation
As part of its commitment to reducing its energy intensity, Saint-Gobain undertook a large compressed air system retrofit project at its Milford, Massachusetts glass plant.
New Paint Plant Showcase Project
Partner: Nissan North America, Inc.
The new paint plant at Nissan’s Vehicle Assembly Plant in Smyrna, Tennessee is 40% more energy efficient than its predecessor.
New Potato Processing Plant Showcase Project
Partner: J.R. Simplot Company
J.R. Simplot’s showcase project is a new, 420,000 square foot, state-of-the-art potato processing plant that will integrate innovative energy-efficient technologies to achieve dramatic energy efficiency improvements of up to 25% while producing hundreds of millions of pounds of frozen potato products per year.
North America Headquarters Showcase Project
Legrand, North America showcased its commitment to energy efficiency by achieving a 11% energy intensity reduction in three years at its 100-year-old West Hartford, Connecticut headquarters facility.
Omnivore Co-Digestion and Recuperative Thickener Showcase Project
Partner: Victor Valley Wastewater Reclamation Authority
Beginning in 2008, Victor Valley Wastewater Reclamation Authority (VVWRA) began planning plant optimization and expansion for its facility to comply with new regulatory limits and increase capacity. VVWRA recognized that in complying with the new regulations they could incorporate project features to reduce future energy costs and eliminate natural gas purchases.
Power Regeneration System Showcase Project
Partner: Briggs & Stratton
Engineers at Briggs & Stratton have pioneered an energy saving solution at the company’s Wauwatosa reliability lab, making it one of the most advanced in the industry.
Recycling Water Using Advanced Filter Strategies Showcase Project
Partner: Nissan North America, Inc.
Nissan's Smyrna plant-paint engineers were searching for ways to reduce water consumption, which is a key part of the manufacturing process, and an automated water filtration system was identified as a possible solution.
Roxboro Gypsum Wallboard Plant Showcase Project
Partner: Saint-Gobain Corporation
CertainTeed Gypsum, a Saint-Gobain subsidiary, furthered its commitment to energy efficiency and the Better Plants Challenge by building a 500,000 square foot state-of-the-art gypsum wallboard manufacturing plant in Roxboro, North Carolina.
Solar Field and Continuous Energy Efficiency Improvement Showcase Project
Partner: Schneider Electric
Schneider Electric is advancing energy efficiency and renewable energy at its Smyrna, Tennessee plant through two major initiatives: 1) the construction of a 1 megawatt (MW) solar farm; and 2) a robust energy management program, which includes certification under the Department of Energy’s Superior Energy Performance (SEP) Program.
Truck Expedition and Navigator Paint Shop Showcase Project
Partner: Ford Motor Company
Traditional Ford Painting Technology uses approximately 860 kWh/vehicle to paint a truck body. Expected energy and energy cost reductions should be 27%, allowing Ford to finish truck bodies using less than approximately 625 kWh/ vehicle.
United Technologies Research Center Showcase Project
Partner: United Technologies Corporation
United Technologies Research Center (UTRC) is a global network of centralized research facilities that support United Technologies Corporation (UTC) business units in developing new technologies and processes. In the summer of 2015, UTC began expanding and renovating its UTRC facility in East Hartford, Connecticut.
Water Retention Pond Showcase Project
The municipal water authority was reluctant to build a bigger water line to supply the HARBEC facility, so the company began searching for alternatives; HARBEC considered installing a 250,000 gallon water tank, before realizing it could dig a retention pond and pipe the water in for the sprinklers, with significant environmental and water saving benefits.