Case Studies
Energy savings achieved by large manufacturing companies using AMO's software tools and information resources are described in case studies. Search the following categories for project ideas and costs. See how significant savings can be achieved with small investments.
- Company Name
- Industry Type (aluminum, automotive, chemicals, forest products, heat treating, metal finishing, textiles, steel)
- System Area (compressed air, electric/natural gas, plant-wide, process heating, steam, sub-metering)
- Special Topics (data centers, utilities, large-company energy assessments, corporate energy management)
Each case study and success story features:
- A summary page with key findings
- Detailed information on manufacturing processes
- Energy savings recommendations
- Results and lessons learned
Company Name
Select a company name from the list to view their energy savings achievements.
A-C
3M:3M has implemented more than 1,900 employee-inspired projects that have realized a 22% improvement in energy efficiency and yielded $100 million in energy savings. Learn about 3M's approach to energy efficiency: 3M's Model Rewards and Recognition Program Engages Employees and Drives Energy Savings Efforts Alcoa:Alcoa's CEO and senior leadership team have made energy efficiency a key priority, and their support is driving an already successful program to new heights. Read more about the full impact of Alcoa's strong corporate leadership: Alcoa: C-Suite Participation in Energy Efficiency Increases Accountability and Staff Engagement Throughout the Organization Alliant Tech Systems, Incorporated (ATK) and Rocky Mountain Power:Boise, Inc.:The Boise Inc. paper mill in St. Helens, Oregon, lowered package boiler stack oxygen levels, modified existing piping to recover waste heat, and reduced the steam supplied to a parasitic load for a simple payback of less than 1 month. Information about the assessment was shared with other Boise Inc. mills: Boise Inc. St. Helens Paper Mill Achieves Significant Fuel Savings Bonneville Power Administration:Through its Energy Smart Industrial program, BPA is informing and assisting utilities and industries to have a better understanding of the benefits that come from participating in energy-savings programs. Read about how BPA is encouraging energy efficiency projects through its utilities: Bonneville Power Administration and the Industrial Technologies Program Leverage Support to Overcome Energy Efficiency Barriers in the Northwest Briggs & Stratton:Briggs & Stratton is working with federal and state agencies, along with local utilities, to implement energy efficiency projects that can help the company meet its Better Plants Program Partner Pledge. Learn more about the costs and benefits of Briggs & Stratton's energy efficiency projects: Briggs & Stratton: Putting All Energy Efficiency Options on the Table Chrome Deposit Corporation:Through strategic partnerships with ITP, the Delaware Manufacturing Extension Partnership, and the University of Delaware's Center for Energy and Environmental Policy, Chrome Deposit Corporation's (CDC's) Newark, Delaware, manufacturing facility explored ways to reduce its energy consumption and environmental impact while continuing to expand its operations. CDC's plant was able to reduce its energy costs by 25% per unit, minimize its environmental impact, and continue to seek novel solutions to energy management. The facility's success is now being used as a benchmark within the company's network of plants. Chrome Deposit Corporation Success Story Chrysler LLC:Chrysler LLC's truck and minivan assembly complex in St. Louis, Missouri, optimized boiler operation, reduced boiler blowdown, and implemented an ongoing steam trap inspection and repair program and achieved a simple payback of just over 2 months. The assessment methodology is also being shared with other Chrysler plants Chrysler: Save Energy Now Assessment Enables a Vehicle Assembly Complex to Achieve Significant Natural Gas Savings Commonwealth Aluminum:Cook Composites and Polymers:Cook Composites and Polymers Company Achieves Superior Energy Performance Gold Certification |
D-I
Danville Utilities:DOE's university-based Industrial Assessment Centers (IACs) performed on-site energy audits of Danville's biggest energy users. IACs helped Danville's customers improve energy efficiency through lean manufacturing and improved process management. A Case Study of Danville Utilities: Utilizing Industrial Assessment Centers to Provide Energy Efficiency Resources for Key Accounts Dow Chemical Company:Repairing steam leaks and replacing nonfunctional steam traps were easy, cost-effective steps that yielded Dow Chemical Company's Hahnville, Louisiana, plant a quick payback. The company also implemented ongoing steam trap maintenance and leak management programs: Dow Chemical Company: Assessment Leads to Steam System Energy Savings in a Petrochemical Plant Eck Industries, Inc.:Working with Wisconsin's Focus on Energy, Eck Industries, Inc. pursued a lighting retrofit project that reduced its facility's electricity use, achieved annual operating savings, and provided higher quality lighting. Learn how Eck Industries, Inc. leveraged state resources to overcome barriers to implementing large-scale energy efficiency projects: Eck Industries, Inc. Realizes Savings Through Smarter Lighting Solutions Flambeau River Papers:After the closure of the Flambeau River Papers mill in 2006, a new energy management approach has resulted in $2.6 million in annual energy savings and increased the facility's production by 11.9%. Read about Flambeau's successful energy management approach: Flambeau River Papers Makes a Comeback With a Revised Energy Strategy Freescale Semiconductor Inc.:Freescale Semiconductor Successfully Implements an Energy Management System FUJIFILM:FUJIFILM Hunt Chemicals U.S.A.'s Dayton, Tennessee, manufacturing plant made improvements to its compressed air system that increased system reliability, reduced system maintenance costs, reduced the facility's overall energy use, and eliminated the use of nitrogen when compressed air systems are down. The Dayton plant is sharing its best practices with other FUJIFILM plants, as well as other industrial stakeholders in the region. FUJIFILM Hunt Chemicals USA Achieves Compressed Air System Energy-Reduction Goals with a Three-Phased Strategy Goodyear:Goodyear's tire plant in Union City, Tennessee, optimized boiler operation, improved load management, and insulated tire presses for a simple payback of 2.5 months. The methodology and results from the assessment are also being shared with and applied to several other Goodyear facilities. Goodyear Tire Plant Gains Traction on Energy Savings After Completing Save Energy Now Assessment Harrison Steel:By leveraging partnerships with AMO's Better Plants (formerly LEADER) and EPA's ENERGY STAR Programs, the Harrison Steel Casting Company has found itself equipped with the full spectrum of tools needed to plan and achieve energy savings. Learn how Harrison Steel has maximized its energy efficiency efforts: Harrison Steel leverages both ENERGY STAR® and Save Energy Now programs to enhance energy efficiency efforts and multiply captured energy savings Ingersoll Rand:In order to meet its Better Plants Program (formerly LEADER) Partner Pledge, Ingersoll Rand is leveraging its internal energy audit program that has already saved more than $4 million in energy costs throughout the company's global operations. Read about Ingersoll Rand's 3-tiered energy audit program: Ingersoll Rand Discovers Hidden Savings with a Three-Tiered Energy Audit Model |
J-O
J.R. Simplot:The J.R. Simplot Company's Don Plant in Pocatello, Idaho, optimized boiler operation, improved condensate recovery, and fixed steam traps and leaks for a simple payback of 6.5 months. Results are being shared with other Simplot facilities and other recommendations identified during the assessment are under consideration. Steam System Efficiency Optimized After J.R. Simplot Fertilizer Plant Receives Energy Assessment Kaiser Aluminum:The Kaiser Aluminum plant in Sherman, Texas, adjusted controls and made repairs to a furnace for a simple payback of 1 month. Kaiser adopted DOE's Process Heating Assessment and Survey Tool (PHAST) software as the corporate diagnostic tool and has used it to evaluate process heating systems at five other aluminum plants. Energy Assessment Helps Kaiser Aluminum Save Energy and Improve Productivity Lucasfilm:A DOE assessment team identified seven ways for Lucasfilm in San Francisco, California, to save energy in its 13,500-square-foot data center. DOE Assessment Evaluates Energy Performance of Film and Entertainment Company Data Center Mid-South Metallurgical:The Mid-South Metallurgical Murfreesboro, Tennessee, plant installed new furnace insulation, implemented an electrical demand system, replaced furnace burner tubes, and made lighting system improvements to achieve energy and cost savings. Mid-South Metallurgical Makes Electrical and Natural Gas System Upgrades to Reduce Energy Use and Achieve Cost Savings Nissan North America:The corporate leadership at Nissan cultivates a culture of energy efficiency, encouraging employees to practice good energy management at work and in every part of their lives. Read about Nissan's energy-conscience culture: Nissan Showcases the Results of an Energy-Wise Corporate Culture The information yielded by the advanced use of sub-meters has enabled data-driven decision making that has resulted in positive outcomes far beyond expectations: Nissan Showcases the Results of an Energy-Wise Corporate Culture Owens Corning and Silicon Valley PowerOwens Corning was able to use help from Silicon Valley Power and the DOE to realize $252,000 in annual energy cost savings, and receive $251,000 in Silicon Valley Power incentives. Owens Corning and Silicon Valley Power Partner to Make Energy Savings a Reality |
P-S
Saint-Gobain:Saint-Gobain developed an approach to help guide other companies on effectively preparing for an Energy Savings Assessment in a manner that will maximize its value and ensure implementation of efficiency improvement recommendations. Learn about Saint-Gobain's approach: Saint-Gobain Shows the Way on Effectively Preparing for Energy Savings Assessments Shaw Industries:The Shaw Industries carpet manufacturing plant #20 in Dalton, Georgia, optimized boiler operation and installed waste heat exchangers on two processes in the dye house and an economizer on one boiler, for a payback of 1.7 years. These results prompted plant #4, also located in Dalton, to participate in an assessment. Save Energy Now Assessment Helps Expand Energy Management Program at Shaw Industries Sherwin Williams:In the Richmond plant's first year as a Better Plants Program (formerly LEADER) Partner, it not only met its 10-year goal, but surpassed it. This partnership proved to be a huge success for Sherwin-Williams, leading the company to make a corporate-wide LEADER Pledge: Sherwin-Williams' Richmond, Kentucky, Facility Achieves 26% Energy Intensity Reduction; Leads to Corporate Adoption of Save Energy Now LEADER Solutia:The use of sub-meters leads to energy efficiency successes for Solutia and paves the way for future projects: Solutia: Utilizing Sub-Metering to Drive Energy Project Approvals Through Data Southern California Gas Company Industrial End User Program:Meeting State Carbon Emission Requirements through Industrial Energy Efficiency Sybase:After implementing energy-saving measures in their Dublin, California, data center, Sybase applied DOE's DC Pro software tools and determined that the savings estimates provided by the tools closely matched the company's realized savings: Database Technology Company Saves $262,000 Annually |
T-Z
Terra Nitrogen:Terra Nitrogen's ammonia and fertilizer plant in Verdigris, Oklahoma, upgraded to more efficient condensing turbines and installed a loop dehydrator. To identify even more energy-saving opportunities, plant employees plan to continually analyze their steam system using DOE's Steam System Assessment Tool (SSAT): Terra Nitrogen Company, L.P.: Ammonia Plant Greatly Reduces Natural Gas Consumption After Energy Assessment U.S. Steel:The U.S. Steel Minntac plant in Mt. Iron, Minnesota, identified energy savings opportunities in its process lines and validated natural gas savings from new burners that were installed prior to the assessment. The success led to additional assessments at U. S. Steel plants in Indiana and Michigan. Largest Producer of Steel Products in the United States Achieves Significant Energy Savings at its Minntac Plant Verizon:Numerous opportunities were pinpointed during a DOE assessment of a Verizon data center that could help reduce energy use and increase reliability: DOE Assessment Identifies 30% Energy Savings for Broadband and Wireless Communication Company Volvo:Volvo's New River Valley facility achieves plant-wide targets that surpass both corporate and Better Plants Program (formerly LEADER) goals; leverages company and DOE resources: Volvo Trucks Achieves Lofty Energy and Carbon Goals West Linn Paper Company:West Linn Paper Company surveyed steam traps, added insulation, and re-evaluated the positioning of several steam headers to achieve savings. The plant, which is located in West Linn, Oregon, is utilizing DOE's Steam System Assessment Tool (SSAT) software to consistently evaluate new projects. Longest-Serving Active Paper Mill in the Western United States Uncovers New Ways to Save Energy |
Industry Type
Select an industry to learn about opportunities for improving energy efficiency.
Aluminum
|
Eck Industries, Inc. Realizes Savings Through Smarter Lighting Solutions Energy Assessment Helps Kaiser Aluminum Save Energy and Improve Productivity |
Automotive
Chemicals
Forest Products
Heat Treating
Metal Finishing
|
Success Story: Chrome Deposit Corporation |
Textiles
Steel
System Area
Select a system area to read about efficiency improvements in energy-intensive manufacturing systems.
Compressed Air
Electric, Natural Gas
Plant-wide
|
Chrome Deposit Corporation Success Story |
Process Heating
Steam
Sub-Metering
Special Topics
Select a topic area to learn about: data center energy savings opportunities, utility partnerships with manufacturers that led to implemented projects that would otherwise not be feasible, large facilities that implemented energy-saving projects identified in assessments, and companies that are establishing energy management programs.
Data Centers
|
A DOE assessment team identified seven ways for Lucasfilm in San Francisco, California, to save energy in its 13,500-square-foot data center. DOE Assessment Evaluates Energy Performance of Film and Entertainment Company Data Center After implementing energy-saving measures in their Dublin, California, data center, Sybase applied DOE's DC Pro software tools and determined that the savings estimates provided by the tools closely matched the company's realized savings: Database Technology Company Saves $262,000 Annually Numerous opportunities were pinpointed during a DOE assessment of a Verizon data center that could help reduce energy use and increase reliability: DOE Assessment Identifies 30% Energy Savings for Broadband and Wireless Communication Company |
Utilities
|
Through its Energy Smart Industrial program, BPA is informing and assisting utilities and industries to have a better understanding of the benefits that come from participating in energy-savings programs. Read about how BPA is encouraging energy efficiency projects through its utilities: Bonneville Power Administration and the Industrial Technologies Program Leverage Support to Overcome Energy Efficiency Barriers in the Northwest Briggs & Stratton is working with federal and state agencies, along with local utilities, to implement energy efficiency projects that can help the company meet its Better Plants Program Partner Pledge. Learn more about the costs and benefits of Briggs & Stratton's energy efficiency projects: Briggs & Stratton: Putting All Energy Efficiency Options on the Table DOE's university-based Industrial Assessment Centers (IACs) performed on-site energy audits of Danville's biggest energy users. IACs helped Danville's customers improve energy efficiency through lean manufacturing and improved process management: A Case Study of Danville Utilities: Utilizing Industrial Assessment Centers to Provide Energy Efficiency Resources for Key Accounts Owens Corning was able to use help from Silicon Valley Power and the DOE to realize $252,000 in annual energy cost savings, and receive $251,000 in Silicon Valley Power incentives. Owens Corning and Silicon Valley Power Partner to Make Energy Savings a Reality Meeting State Carbon Emission Requirements through Industrial Energy Efficiency |
Energy Assessments
|
3M has implemented more than 1,900 employee-inspired projects that have realized a 22% improvement in energy efficiency and yielded $100 million in energy savings. Learn about 3M's approach to energy efficiency: 3M's Model Rewards and Recognition Program Engages Employees and Drives Energy Savings Efforts Alcoa's CEO and senior leadership team have made energy efficiency a key priority, and their support is driving an already successful program to new heights. Read more about the full impact of Alcoa's strong corporate leadership: Alcoa: C-Suite Participation in Energy Efficiency Increases Accountability and Staff Engagement Throughout the Organization Through its Energy Smart Industrial program, BPA is informing and assisting utilities and industries to have a better understanding of the benefits that come from participating in energy-savings programs. Read about how BPA is encouraging energy efficiency projects through its utilities: Bonneville Power Administration and the Industrial Technologies Program Leverage Support to Overcome Energy Efficiency Barriers in the Northwest Briggs & Stratton is working with federal and state agencies, along with local utilities, to implement energy efficiency projects that can help the company meet its Better Plants Program Partner Pledge. Learn more about the costs and benefits of Briggs & Stratton's energy efficiency projects: Briggs & Stratton: Putting All Energy Efficiency Options on the Table Working with Wisconsin's Focus on Energy, Eck Industries, Inc. pursued a lighting retrofit project that reduced its facility's electricity use, achieved annual operating savings, and provided higher quality lighting. Learn how Eck Industries, Inc. leveraged state resources to overcome barriers to implementing large-scale energy efficiency projects: Eck Industries, Inc. Realizes Savings Through Smarter Lighting Solutions After the closure of the Flambeau River Papers mill in 2006, a new energy management approach has resulted in $2.6 million in annual energy savings and increased the facility's production by 11.9%. Read about Flambeau's successful energy management approach: Flambeau River Papers Makes a Comeback With a Revised Energy Strategy By leveraging partnerships with AMO's Better Plants (formerly LEADER) and EPA's ENERGY STAR Programs, the Harrison Steel Casting Company has found itself equipped with the full spectrum of tools needed to plan and achieve energy savings. Learn how Harrison Steel has maximized its energy efficiency efforts: Harrison Steel leverages both ENERGY STAR® and Save Energy Now programs to enhance energy efficiency efforts and multiply captured energy savings In order to meet its Better Plants Program (formerly LEADER) Partner Pledge, Ingersoll Rand is leveraging its internal energy audit program that has already saved more than $4 million in energy costs throughout the company's global operations. Read about Ingersoll Rand's 3-tiered energy audit program: Ingersoll Rand Discovers Hidden Savings with a Three-Tiered Energy Audit Model The corporate leadership at Nissan cultivates a culture of energy efficiency, encouraging employees to practice good energy management at work and in every part of their lives. Read about Nissan's energy-conscience culture: Nissan Showcases the Results of an Energy-Wise Corporate Culture The information yielded by the advanced use of sub-meters has enabled data-driven decision making that has resulted in positive outcomes far beyond expectations: Nissan North America: How Sub-Metering Changed the Way a Plant Does Business Saint-Gobain developed an approach to help guide other companies on effectively preparing for an Energy Savings Assessment in a manner that will maximize its value and ensure implementation of efficiency improvement recommendations. Learn about Saint-Gobain's approach: Saint-Gobain Shows the Way on Effectively Preparing for Energy Savings Assessments In the Richmond plant's first year as a Better Plants Program (formerly LEADER) Partner, it not only met its 10-year goal, but surpassed it. This partnership proved to be a huge success for Sherwin-Williams, leading the company to make a corporate-wide LEADER Pledge: Sherwin-Williams' Richmond, Kentucky, Facility Achieves 26% Energy Intensity Reduction; Leads to Corporate Adoption of Save Energy Now LEADER The use of sub-meters leads to energy efficiency successes for Solutia and paves the way for future projects: Solutia: Utilizing Sub-Metering to Drive Energy Project Approvals Through Data Volvo's New River Valley facility achieves plant-wide targets that surpass both corporate and Better Plants Program (formerly LEADER) goals; leverages company and DOE resources: Volvo Trucks Achieves Lofty Energy and Carbon Goals |
Corporate Energy Management
|
Alcoa's CEO and senior leadership team have made energy efficiency a key priority, and their support is driving an already successful program to new heights. Read more about the full impact of Alcoa's strong corporate leadership: Alcoa: C-Suite Participation in Energy Efficiency Increases Accountability and Staff Engagement Throughout the Organization Through its Energy Smart Industrial program, BPA is informing and assisting utilities and industries to have a better understanding of the benefits that come from participating in energy-savings programs. Read about how BPA is encouraging energy efficiency projects through its utilities: Bonneville Power Administration and the Industrial Technologies Program Leverage Support to Overcome Energy Efficiency Barriers in the Northwest Through strategic partnerships with AMO, the Delaware Manufacturing Extension Partnership, and the University of Delaware's Center for Energy and Environmental Policy, Chrome Deposit Corporation's (CDC's) Newark, Delaware, manufacturing facility explored ways to reduce its energy consumption and environmental impact while continuing to expand its operations. CDC's plant was able to reduce its energy costs by 25% per unit, minimize its environmental impact, and continue to seek novel solutions to energy management. The facility's success is now being used as a benchmark within the company's network of plants. Chrome Deposit Corporation Success Story Cook Composites and Polymers Company Achieves Superior Energy Performance Gold Certification DOE's university-based Industrial Assessment Centers (IACs) performed on-site energy audits of Danville's biggest energy users. IACs helped Danville's customers improve energy efficiency through lean manufacturing and improved process management: A Case Study of Danville Utilities: Utilizing Industrial Assessment Centers to Provide Energy Efficiency Resources for Key Accounts After the closure of the Flambeau River Papers mill in 2006, a new energy management approach has resulted in $2.6 million in annual energy savings and increased the facility's production by 11.9%. Read about Flambeau's successful energy management approach: Flambeau River Papers Makes a Comeback With a Revised Energy Strategy Freescale Semiconductor Successfully Implements an Energy Management System The corporate leadership at Nissan cultivates a culture of energy efficiency, encouraging employees to practice good energy management at work and in every part of their lives. Read about Nissan's energy-conscience culture: Nissan Showcases the Results of an Energy-Wise Corporate Culture Owens Corning was able to use help from Silicon Valley Power and the DOE to realize $252,000 in annual energy cost savings, and receive $251,000 in Silicon Valley Power incentives. Owens Corning and Silicon Valley Power Partner to Make Energy Savings a Reality The Shaw Industries carpet manufacturing plant #20 in Dalton, Georgia, optimized boiler operation and installed waste heat exchangers on two processes in the dye house and an economizer on one boiler, for a payback of 1.7 years. These results prompted plant #4, also located in Dalton, to participate in an assessment. Save Energy Now Assessment Helps Expand Energy Management Program at Shaw Industries Meeting State Carbon Emission Requirements through Industrial Energy Efficiency |