Case study describing a project which configured a printing machine so that it consumes less compressed air and required lower pressure to operate effectively. Project replicated throughout the company, leading to energy cost savings of $200,000 per year, or 2.9 million kilowatt-hours.

This case study highlights International Truck and Engine Corporation's optimization project on the compressed air system that serves its foundry, Indianapolis Casting Corporation. Due to the project's implementation, the system's efficiency was greatly improved, allowing the foundry to operate with less compressor capacity, which resulted in reduced energy consumption, significant maintenance savings, and more reliable production.

This case study describes an optimization project implemented on a fan system at Ash Grove Cement Company, which led to annual energy and maintenance savings of $16,000 and 175,000 kilowatt-hours (kWh). In 1999, Ash Grove Cement Company implemented an optimization project on a fan system in its cement plant in Durkee, Oregon. Because of a severe vibration problem, the fan system would often fail and require frequent repairs to the ductwork and adjoining machinery. The plant replaced the belt drive with an Adjustable Speed Drive (ASD) to improve the control of the fan system and lower its energy consumption. This change eliminated the vibration problem and improved the system's airflow control and energy efficiency. The project led to annual energy and maintenance savings of $16,000 and 175,000 kilowatt-hours (kWh). In addition, the fan system's improved reliability allowed the plant to achieve its desired production level. Because of partial funding from the Northwest Energy Efficiency Alliance (NEEA), the total project cost was approximately $10,000, which gave the Durkee plant a simple payback of 7.5 months.

3M conducted an in-house motor system study in 29 buildings at the 3M Center. The company evaluated approximately 1,000 electric motors and upgraded systems, resulting in reduced electricity use and cost savings of $77,554 per year.

Review of pumping system at paper mill led to installation of mechanical Adjustable Speed Drives on two pumps, which resulted in annual energy savings of $32,000 and 700,000 kilowatt hours.