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U.S. Plastics Manufacturers Stand to Save Energy, Boost Competitiveness, and Reduce Costs

The plastics industry consumes approximately 6% of all the energy used by U.S. industries, and it is valued at $6 billion (based on 1998 DOE and other data). DOE estimates that reducing the plastics industry's energy use by even 1% by 2010 could shave at least $100 million from its total annual energy costs.

In 2003, DOE and The Society of the Plastics Industry, Inc. (SPI) formed a partnership to identify the potential for plastics manufacturers to reduce their overall energy use, enhance productivity, and save money. They worked on a series of energy assessments conducted by seven DOE-sponsored Industrial Assessment Centers (IAC) at 11 SPI member companies.

The major finding of this effort is that U.S plastics manufacturing companies can boost their competitiveness, productivity, and profits by taking steps to improve energy and process efficiency. The report and case studies below describe the results of these assessments at the small and medium-sized plastics plants that were the focus of this effort. Those that have implemented IAC recommendations are already saving an average of $45,000—or nearly 10%—on their energy annual energy bills.

Read the report and case studies to find out how these recommendations could be adapted and replicated throughout the U.S. plastics industry.

Full Report

  • Improving Energy Efficiency at U.S. Plastics Manufacturing Plants

    Summary Report and Case Studies (PDF 1 MB)

Stand-Alone Case Studies

  • Bemis Manufacturing Company

    Compression Molding Company Saves More Than $22,000 Per Year by Implementing Industrial Assessment Recommendations (PDF 142 KB)

  • Dickten & Masch Manufacturing Company

    Industrial Energy Assessment Achieves $35,000 in Savings for Plastics Manufacturer (PDF 139 KB)

  • Ferro Corporation

    Industrial Energy Assessment Identifies $210,000 in Cost Savings Opportunities for Glaze and Coatings Manufacturer (PDF 121 KB)

  • Moraine Molded Plastics, Inc.

    Industrial Energy Assessment Finds Opportunities to Save $24,000 in Annual Operating Costs (PDF 131 KB)

  • National Plastics Corporation

    Energy Assessment Helps Automotive Plastic Parts Maker Save $34,000 Per Year (PDF 121 KB)

  • N-K Manufacturing Technologies

    Industrial Energy Assessment Yields Savings of More Than $27,000 Per Year for Molded Plastics Company (PDF 122 KB)

  • Precise Technology, Inc.

    Molded Plastics Manufacturer's Energy Use Drops 22% as a Result of Industrial Energy Assessment Recommendations (PDF 134 KB)

  • Spartech Plastics

    North American Thermoplastic Extruder Implements Industrial Assessment Findings and Saves More Than $100,000 Per Year (PDF 117 KB)

  • Superfos Packaging

    Plastics Manufacturer Saves $100,000 Per Year by Implementing Industrial Energy Assessment Recommendations (PDF 133 KB)

  • VPI Corporation

    Industrial Energy Assessment Helps Manufacturer Start Saving $7,000 in Less Than a Year (PDF 115 KB)

  • Wexco Corporation

    Assessment Uncovers $53,000 in Energy Efficiency Opportunities at Plastic Extrusion Cylinder Manufacturer (PDF 123 KB)