Insights

As a manufacturer of private label food products, this Midwestern plant has always been focused on operational efficiency, producing products at the lowest total cost, and implementing best practice programs. In the past, they have relied on Nalco Water as their partner to bring them ideas and perspectives from projects we see across the industry and utilize our expertise to help develop cost savings projections. In addition, the company has sustainability goals to reduce greenhouse gas emissions by 5% over a 5-year period. 

Actions

As their trusted partner, Nalco Water came to them with an opportunity to reduce their compressed air electricity spend by an estimated 17% annually, equating to an approximate savings of $48,000 and 424 metric tons in carbon emissions. Nalco Water partnered with Ecoplant to implement Ecoplant 360, a machine-learning monitoring and control network that optimizes generation of compressed air. 

Outcomes

Within the first five months of operation, the Ecoplant 360 system exceeded expectations and delivered a 21% reduction in energy used within the plant’s compressed air system, and a 6% reduction in the overall plant energy bill. 

• Energy: monthly savings 69,164 kWh = $5,533
• Greenhouse gases: 587 metric tons of CO2 emissions saved annually
• Value delivered: $66,397 annually