Save Energy Now Assessment Leads to Savings of $827,000 for Shaw Industries

July 9, 2008

Part of the corporate culture at Shaw Industries emphasizes energy efficiency and environmental stewardship. Plant employees at the #20 carpet-making plant in Dalton, Georgia, were open to new options for potential energy-saving measures when they participated in a U.S. Department of Energy (DOE) Save Energy Now energy assessment. The assessment provided several recommendations that were implemented for annual cost savings of $872,000 and energy savings of 93,000 MMBtu in natural gas and No. 6 fuel oil.  

Energy Expert George Lee, of the Georgia Institute of Technology, used DOE’s Steam System Assessment Tool (SSAT) software to model the plant’s steam system and identify seven opportunities for increased energy savings. Plant personnel implemented several assessment recommendations and altered another. They optimized boiler operation to fully load the most efficient boiler and installed waste heat exchangers on two processes in the dye house, and installed an economizer on one of the boilers and de-scaled boiler tubes. In place of a hot water heater on the Kuster dye line, plant personnel used sparged steam to heat the water back to its required temperature.  

“Our plant was very fortunate to be selected for the U.S. Department of Energy Save Energy Now study,” said Shaw Industries’ plant engineer Robert Davidson. “With rising fuel costs and ever advancing competition, the need to be as energy efficient as possible is paramount. This study helped to shine the light on both large and small opportunities to become more efficient. The results speak for themselves.”    

To learn more about Shaw Industries’ plant #20 assessment, including energy savings recommendations that can be applied to your plant, read the full case study (PDF 532 KB). Download Adobe Reader. See additional Save Energy Now case studies.  

Apply today for a Save Energy Now energy assessment to start saving energy in your plant. If you already participated in an assessment, be sure to implement the recommendations and complete an assessment report with your DOE Energy Expert.