Carlisle SynTec, Inc.
Greenville, Illinois
Intern: Brady Stewart
Southern Illinois University, Edwardsville
Carlisle SynTec, Inc. manufactures single-ply EPDM rubber roofing and
other pressure-sensitive rubber products. The firm has been operating
in Greenville since 1980.
The intern project was designed to identify energy efficiency opportunities
throughout the facility. The intern also researched opportunities to
minimize waste and reduce discharges to the local municipal wastewater
treatment plant.
Results:
The intern identified the following energy efficiency opportunities:
- By replacing T-12 fluorescent light fixtures with T-8 fixtures in
the office area, would result in saving the company $4,300 per year
with a 2-year payback
- By replacing metal halide fixtures with 4-lamp T-5 fixtures in the
warehouse, would result in saving $23,000 per year with a 4-year payback.
- In the compressed air system:
- Repair air leaks that could result in saving the company $1,000
a year.
- Install sequencers on the four air compressors to save $13,000
a year with a one-year payback.
- Install a pressure regulator to reduce plant air pressure to
100 psig. This would save the company $4,635 a year with a 2.3
year payback.
- Use the existing 50-hp compressor on Sundays and holidays, which
has the potential to save the company an additional $17,000 a year.
- Establish a program to recycle the semi-cured rubber waste stream.
This would produce a savings in disposal costs of over $23,000 a year.
- The current water tube boiler at the facility has an efficiency of
60% and was oversized for future expansion that never occurred. Purchasing
a fire tube boiler to match current steam production can save the company
over $100,000 with a 1-year payback.
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