Using MotorMaster+ Software, a Kodak Plant in New York Saves About $660,000 Annually

October 20, 2006

Because motor-driven systems can consume a significant amount of electricity, staff in Kodak's chemical and imaging technologies plant in Rochester, New York, launched a Total Motor Program (TMP) in 1995 that has been very successful in helping the plant save energy and money. At first, the program's focus was to consolidate the plant's inventory of motors and spare parts. Then, the TMP began focusing on ways to improve the energy efficiency of the plant's motors.

Between 40,000 and 50,000 motors are used in the plant's production processes at any given time, so there is tremendous potential for savings. Using the U.S. Department of Energy's (DOE) Industrial Technologies Program MotorMaster+ software tool, plant engineers established a system for assessing motor efficiency and evaluating the energy savings potential of new motors. Since 2002, the plant has installed about 600 new NEMA Premium™ efficiency motors, saving 5.8 million kWh and about $664,000 annually in energy and maintenance costs.

The Rochester location houses Kodak's corporate headquarters and its largest U.S. manufacturing facility, among other functions. Originally developed more than 100 years ago, the site covers eight square miles and contains 20 million square feet of building space. The Rochester plant has already shared its motor efficiency program and experiences with another plant in Windsor, Colorado. Establishing a program like Kodak's TMP could help many facilities better manage their motor systems and identify opportunities for energy efficiency and cost savings.

MotorMaster+ contains a catalog of more than 20,000 AC motors and includes motor inventory management tools as well as methods for maintenance log tracking, efficiency analysis, savings evaluations, energy accounting, and environmental reporting. Plants can obtain MotorMaster+ free of charge either online or by calling the EERE Information Center (1-877-337-3463).

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