CEERE Success Stories
Industrial Assessment Center
Since 1984, the UMass Industrial Assessment Center has conducted more than no-cost 800 assessments for a wide range of manufacturing facilities across the northeast. Here are some of our recent success stories:
Our team conducted an assessment of the Stanley Black & Decker facility in New Britain, Connecticut in 2014. The company is now saving $28,900 annually by implementing our recommendations to install variable frequency drives on injection molding machines, eliminate an unnecessary use of energy-intensive compressed air, insulate the boiler condensate tank, and select high-efficiency models when purchasing new injection molding machines. The energy savings paid for the implementation cost in 2.3 years after incentives from Eversource. Two years later, the company was continuing to consider implementation of some of our other recommendations.
In a 2013 assessment of a 22,000 square foot commercial bakery, we made nine recommendations, including heat recovery from oven exhaust, HVAC and compressed air system improvements, and lighting upgrades. The company implemented all of our recommendations, which resulted in annual savings of $83,500 with a payback period of less than two years.
In 2015, we conducted an assessment of the Philips Lightolier (a division of Philips Lighting) facility in Fall River, Massachusetts. While the facility had ongoing efforts to increase efficiency and reduce waste, our team was able to identify 12 new recommendations for further savings. Philips saved $102,000 annually by implementing several of our recommendations, including improvements to their compressed air system and installation of variable frequency drives to optimize operation of pumps and fans. After utility incentives toward implementation costs, the energy savings paid for the company's investment in just a few months.
In 2011, our team conducted an assessment of Ball’s Saratoga, NY facility, which manufactures aluminum beverage cans. The company implemented all seven of our recommendations, resulting in total annual savings of approximately $215,000, with a payback period of less than one year.
Combined Heat and Power
Our center has conducted more than no-cost 130 CHP feasibility studies over the past 15 years. Following are examples of successful CHP installations we have assisted with:
In 2009, a new central heating plant began operating here on the UMass Amherst campus. We were involved in two aspects of the plant's design: (1) using modeling software to optimize system size and performance, which allowed the designers to reduce the number of package boilers installed in the plant from the four initially planned to three, and (2) modeling the steam distribution system to provide physical plant managers an opportunity to evaluate system performance and evaluate potential modifications. Since then, we have continued to work with physical plant staff on system optimization.
In a facility-wide assessment through the IAC program, we identified an opportunity to reduce operating costs at the Seaman Paper facility in Otter River, Massachusetts by installing a wood-first CHP system. The company was interested in pursuring that recommendation further, so we then conducted a more in-depth CHP feasibility study. The CHP system was installed in 2009 and it has saved the company over $1.5 million annually.