DICKEY-john Corporation
Auburn, Illinois
Ruby Khan
Bradley University, Peoria
DICKEY-john Corporation is located in Auburn, Illinois. This firm makes
electronic sensing devices for agricultural, off-highway and public works operations. The
main part of the plant consists of a 200,000 square-foot facility, which employs
350 people.
The intern conducted an energy assessment at the facility and made recommendations
on ways the company could reduce electricity usage through energy efficiency
measures.
Anticipated Results:
The student made the following recommendations for the compressed air system:
- Reducing the compressor system’s air pressure to 95 psig could result
in a savings of $1,800 a year.
- Using outside air for the compressor intake has the potential to save $900
a year.
- Fixing air leaks in the compressed air system can save over $13,500 a year.
- Installing a VFD motor on the air compressor could save $16,800 a year.
- Installing a smaller air compressor that would only operate occasionally
at night and weekends could potentially save over $10,000 a year.
In the electroplating area, the following changes were recommended:
- Replacing the water sensor on the rinse water tanks could save $14,000
a year.
- Installing covers on the plating holding tanks to minimize high humidity
levels in the work area and loss of heating could save $2,000 a year.
Other energy efficiency recommendations included:
- Replacing T12 lights with T8 lights and electronic ballasts could save
over $34,000 a year.
- Use gas heaters for load shed could save over $27,000 a year.
- Installing an air-to-air heat exchanger on the exhaust from the bake oven
in the powder coating process. This could save over $12,000 a
year.
Actual Results: Through July 2007
- Approximately one-half of the compressed air leaks have been repaired,
though there has been no effort to classify leaks according to size.
- New sensors were installed on the plating tanks. We have requested that
covers be used on the tanks without any success.
- New ballasts and lamps have been purchased to replace all of the T-12 lamps
in the factory; we are about half way through the conversion of 600 light
fixtures.
- The ballasts and lamps were purchased from a broker that sold the entire
electric inventory from the K’s Merchandise bankruptcy.
- We expect labor and disposal costs to offset any electricity savings
for the first couple of years.
|
