Alcan Packaging
Centralia, Illinois
Intern: Jacob Hassan
Indiana University, Bloomington IN
The Alcan Packaging facility in Centralia produces plastic bottles using an injection blow mold process. The facility employs 250 people, with 37 blow mold machines and 12 decorating machines that run 24 hours, seven days a week. Alcan Packaging grossed over $12 billion in 2002 and operates facilities in 41 countries.
The intern conducted research on energy efficiency alternatives for the lighting, compressed air, flame treatment and chiller/HVAC systems.
Results:
The intern recommended the following energy efficiency projects:
- Replace T-12 fluorescent light fixtures with T-8 fixtures. This project is estimated to save $2,000 a year with a payback period just over 2 years.
- Repair air leaks in the four compressed air systems. This project is estimated to save nearly $33,000.
- Replace the mold core rod conditioning hoses in the compressed air systems. This could save $4,800 annually in reduced energy expenditures. Additional compressed air savings could be realized by replacing 31 air diverters with mechanical driven actuators. This project could save $4,400 a year with a payback period of less than a year and one-half.
- Shut down the 300-ton chiller, which provides chilled water to air compressors, blow mold machines and the air conditioning units on the plant floor. Install a geothermal system to provide air conditioning and keep the other two chillers operating. Raise the chilled water temperature to 50 degree F for the blow mold machines. Together, these projects could save Alcan an estimated $79,000 a year in refrigeration costs.
|
