Warehouse and Manufacturing

Stock up on energy ideas.

DTE Energy can maximize your energy usage and savings in large facilities.

Both dry and cold storage facilities can lower their utility costs by implementing energy-efficiency measures that strengthen their bottom lines. In addition to lighting, heating and refrigeration, we have ideas and incentives tailored for loading areas, air circulation and more.

Data from U.S. Energy Information Administration

The largest operating expense for Art Van Furniture is utilities. DTE helped the retailer cut those costs by 40% after one year through our Energy Efficiency Program for Business.

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Located in Auburn Hills, Michigan, Broner Hat and Glove changed lighting in its offices and distribution center, and added motion detectors, for an estimated 15% monthly energy savings.

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DTE Energy can help your bottom line with incentives – prescriptive, custom or new construction -- that can substantially reduce the cost of your business projects.

Compressed Air

Fix leaks in air distribution systems
Air leaks can be a significant source of wasted energy. A typical plant that has not been well maintained could have a leak rate from 20% to 50% of total compressed air production capacity. Leak repair and maintenance can reduce this number to less than 10%. Overall, fixing leaks in a compressed air system is projected to reduce annual energy consumption by 20%.

Turn off equipment that is no longer using compressed air
Turn off equipment using a simple solenoid valve. Check compressed air distribution systems when equipment has been reconfigured to ensure no air is flowing to unused equipment or obsolete parts of the compressed air distribution system.

Blocked pipeline filters increase pressure drop
Blocked pipeline filters increase pressure drop. Keep the compressor and intercooling surfaces clean and foul-free by inspecting and periodically cleaning filters. Use filters with just a 1 pound per square inch (psi) pressure drop. The payback period for filter cleaning is usually less than 2 years. Fixing improperly operating filters will also prevent contaminants from entering into tools, which causes them to wear out prematurely.

Proper monitoring of compressed air systems can save energy and money
Proper monitoring includes the following: Pressure gauges on each receiver or main branch line, and differential gauges across dryers and filters, temperature gauges across the compressor and its cooling system to detect fouling and blockages, flow meters to measure the quantity of air used, dew point temperature gauges to monitor air dryer effectiveness, and kilowatt-hour meters and hours-run meters on the compressor drive.

Use compressed air mindfully
Compressed air is one of the least energy-efficient systems in an industrial plant because of the amount of energy required for compression and distribution. If compressed air is used, it should be at the minimum quantity for the shortest possible time, and it should be constantly monitored and reweighed against alternatives.

Use lowest possible pressure levels
Try to use the lowest possible pressure level to operate the system to save energy and money.

Source for all the above Compressed Air tips: energystar.gov and Business Energy Advisor.

 

HVAC

Use flue gas monitors to control boiler processes
Flue gas monitors maintain optimum flame temperature and monitor carbon monoxide (CO), oxygen, and smoke in boiler systems. A small 1% air infiltration will result in 20% higher oxygen readings. A higher CO or smoke content in the exhaust gas is a sign that there is insufficient air to complete fuel burning. Using a combination of CO and oxygen readings, it is possible to optimize the fuel/air mixture for high flame temperature (and thus the best energy efficiency) and lower air pollutant emissions.

Repair boiler and flue leaks
Often excessive flue gas results from leaks in the boiler and/or in the flue. These leaks can reduce the heat transferred to the steam and increase pumping requirements. However, such leaks are often easily repaired, saving 2% to 5% of the energy formerly used by the boiler.

Return condensate to boiler
Reusing hot condensate in boilers saves energy, reduces the need for treated boiler feed water, and reclaims water at up to 212°F of sensible heat.

Improve boiler system operations
Designing the boiler system to operate at the proper steam pressure can save energy by reducing stack temperature, piping radiation losses, and leaks in steam traps. Costs and savings will depend heavily on the current boiler system utilization at individual plants.

Repair steam distribution system leaks
As with steam traps, steam distribution piping networks often have leaks that can go undetected without a regular inspection and maintenance program. The U.S. Dept. of Energy estimates that repairing leaks in an industrial steam distribution system will lead to energy savings of 5% to 10%.

Source for the above HVAC tips: energystar.gov and Business Energy Advisor.

Motors

Improve motor operations
For equipment that runs at different speeds, consider installing Adjustable-Speed Drives (ASD) or Variable-Speed Drives (VSD) to better match speed to load requirements for motor operations, and therefore ensure that motor energy use is optimized to a given application. Energy savings may vary from 7% to as high as 60%.

Improve motor cooling
Poor motor cooling can increase motor temperature and wind resistance, shortening motor life and increasing energy consumption. Keep motors and compressors properly lubricated and cleaned.

Manage all of your motor systems
Motors are found in your process equipment, HVAC systems, air compressors, and other systems.

Implement a motor management plan
A motor management plan is another essential part of a plant’s energy management strategy. It helps to support long-term motor system energy savings and to ensure that motor failures are handled quickly and cost effectively.   The national campaign suggests the following actions for a sound motor management plan (MDM 2007): Prepare for motor failure by creating a spares inventory, develop a purchasing specification, develop a repair specification, develop and implement a predictive and preventive maintenance program, develop guidelines for proactive replace/repair decisions.

Source for all the above ‘Motors’ tips: energystar.gov and Business Energy Advisor.

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