Drug Plastics & Glass Company, Inc. Oxford, Indiana Advancing Manufacturing Summit VIII: The Economic and Environmental Benefits of Sustainable Manufacturing Wednesday March 25, 2009 Purdue University – West Lafayette, Indiana

TAP (WIRE) TIME LINE TAP (WIRE) TIME LINE  Sign on to TAP (WIRE) program (Oct 07)  Initial TAP Plant Visit/Assessment (Nov 07)  Plant Energy Team Formed (Nov 07)  Metrics for Success (Dec 07)  WIRE Energy Training (07 & 08)  Implementation of Best Practices (07 & 08)  Control & Sustainment (08 & Beyond)

PROGRAM RESULT PROGRAM RESULT ANNUAL SAVING IN 2008 = $101,180

ENERGY COST SAVING INITIATIVES ENERGY COST SAVING INITIATIVES AAAAIR COMPRESSORS VVVVFD (CHILLED & TOWER WATER) LLLLIGHTING (T-5 FIXTURES) HHHHVAC MMMMOTORS MMMMATERIAL HANDLING WWWWASTE REDUCTION (RECYCLING)

AIR COMPRESSORS Audit for air leaks on monthly scheduleAudit for air leaks on monthly schedule Replaced air cooled compressors with water cooled unitsReplaced air cooled compressors with water cooled units Purchased air sequencerPurchased air sequencer Adopted pro-active & predictive maintenance programAdopted pro-active & predictive maintenance program Replaced bad pipingReplaced bad piping  BEFORE = 7 ATLAS AIR COOLED TOTAL 310 HP  Maximum Output  NOW = 2 KAISERS WATER COOLED HP

LIGHTING (HID VS T-5) REPLACED 105 HIGH BAY LAMPS WITH T-5 FIXTURES

HVAC (Moisture On Roof) IR Camera

PREMIUM VS STANDARD EFFICIENCY MOTORS

WHAT WE LEARNED WHAT WE LEARNED  OVERCOMING THE SKEPTICS  SIX SIGMA APPROACH (DATA DRIVEN)  TRAINING & MORE TRAINING  PLANNING & EXECUTION  MEASURE TWICE CUT ONCE  GET THE RIGHT PEOPLE ON THE TEAM  CONTROL & SUSTAIN  INVOLVE HOURLY PERSONNEL  CONTINOUS TRAINING & IMPROVEMENT  DEVELOP A SYSTEM OF SELF AUDIT  ENERGY METRICS

QUESTIONS? QUESTIONS? THANK YOU…..