North American Operations Kalamazoo Plant Welcome to Kalamazoo
North American Operations Kalamazoo Plant In January, 2009, the Kalamazoo plant management staff met on a Saturday along with plant maintenance, electricians, controls engineers and an outside HVAC vendor to go on a “treasure hunt” to identify areas where Kalamazoo was “wasting energy” in the plant. This process works well, especially on weekends when everything should be off, to assess what’s running and to start asking questions – How can it be shut off? Should it be shut off? Why isn’t it shut off? Areas of opportunity that we looked at were lighting, compressors, HVAC (heating, ventilation, air conditioning), variable frequency drives, weld gas loss due to leakage during non production hours and equipment left on or idle. The Treasure Hunt
North American Operations Kalamazoo Plant Impacts and Incentives Incentives of up to $200K (achieved $152K) from Consumers Energy based on calculated savings of projects Growing energy costs of up to 10% per year Reduction in Peak charges associated with electrical costs – Up to $300K/year Long term gas and electrical savings to reduce plant overhead and make Kalamazoo more cost effective for customers Removing Waste from process ISO Target and Objective Goal for 5 year business plan Move towards being a “Green” plant
North American Operations Kalamazoo Plant Controls System Tridium AX Jace Controllers for communication of all equipment Tridium Web supervisor with corporate license to add other facilities Added (13) Variable Frequency Drives on Exhaust Fans Added (12) Variable Frequency Drives on Dust Collectors Temperature controls and scheduling for (14) Roof Top Units (HVAC) Temperature controls and scheduling for (8) Make-up Air Units Paintline Oven and Burner controls upgrades to control temperature and schedule down time Electrical Metering for all substations with history data to reduce electrical draw and peak charges
North American Operations Kalamazoo Plant Controls System
North American Operations Kalamazoo Plant Gas and Electric Savings
North American Operations Kalamazoo Plant Gas and Electric Savings
North American Operations Kalamazoo Plant Gas and Electric Savings
North American Operations Kalamazoo Plant Conclusion Gas Savings (Jan-Dec) $270,000 or 46% Reduction MMBTU Reduction - 36 % 13% Higher Sales Total Savings 2010: 490K Project Payback = 1.3 Years Electric Savings (Jan-Dec) Lowered parts per KWH from 4.10 to % reduction in Electrical Costs 13% Higher Sales 2 large launches with zero sales Sept- Dec
North American Operations Kalamazoo Plant Project Details/Incentives 1.Get Baseline Data 2.Submit application early with a review with consumers previous to beginning project 3.Maintain all previous consumption reductions with data 4. Submit applications for incentives early