For seventy-five years, Bally Refrigerated Boxes has manufactured refrigeration products, such as walk-in coolers, refrigerated buildings, blast chillers and mortuary coolers. Because of their strong and ingrained energy-saving philosophy, the company initiated an energy efficiency program around its compressed air system that included:
- Right-sizing an off-peak compressed air system;
- Upgrading the main compressor to take advantage of variable speed drive technology and energy recovery; and
- Planning long-term maintenance.
The company uses compressed air for a variety of processes, such as powering metal working presses, shears and stampers, holding molds closed to allow expansion of the polyurethane foam injection and operating several small hand tools pneumatically during the main operating hours. In addition, certain critical systems need compressed air even when the facility is shut down at night and on weekends.
To determine the right size compressor needed to complete the job, the company brought in Atlas Copco to perform an MBox energy audit, which collects data over a seven day operating period. From the study, the company added a compressor that operates efficiently on the weekends, reducing the operating hours of the existing compressors.
To sweeten the deal of purchasing new equipment, the company’s utility provider offered a rebate of $26,000 that covered a year’s worth of energy savings and installation costs. When they calculated the out-of-pocket cost plus the annual energy savings of the new equipment, the project paid for itself in three months.
Have you developed an energy efficiency program at your facility? Tell us about it in the comments below or contact us if you’d like to learn more about performing an MBox energy profile.
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