Vapor Bus International
Buffalo Grove, Illinois
Intern: Joe Bisognani
Southern Illinois University, Carbondale
Vapor Bus International specializes in the manufacturing of passenger bus
door systems and related accessory systems for the transit bus industry. The
Buffalo Grove manufacturing facility has over 120,000 square feet of office
space, manufacturing operations and warehouse areas.
The intern assisted in a coolant recycling project, as well as a wide variety
of energy efficiency projects.
Results:
The intern worked on the following projects and made the following recommendations:
- Assisted
engineering in completing an appropriation request for a new coolant recycling
system. This project would include switching to another coolant and extending
the life of the coolant. This could save the company $28,000 per year in
reduced disposal costs.
- Continue to update the air conditioning (A/C) units and controls.
The facility is in the process of replacing 10 rooftop A/C units that are
over 15 years old. Three units have already been replaced. By modifying automated
controls to run these units fewer hours and three new, more efficient units,
the facility has the potential to save over $23,000 a year.
- Install a thermal
insulation skin on the aluminum paint line oven to reduce conductive heat
losses. Savings would be over $10,000 a year.
- Install an economizer for exhaust heat
recovery on the paint line. This project has the potential to save over $8,000
a year
- Install occupancy sensors in office areas. This could save $7,000
a year. Additional lighting upgrades in the offices could save $500 a year.
- Rewire
the lighting system in the manufacturing shop, so that several lights can
be shut off during 2nd shift. This could save over $3,000 per year.
- Drafted
a "Green Office" standard operating procedure to encourage employees to manually
shut down computers and monitors when not in use for extended periods of
time. This could save the company over $2,000 per year.
- Utilize an ultrasonic leak
detector to identify compressed air leaks and tag them for maintenance to
repair. Over $1,000 per year could be saved.
- Turn off the A/C and the heating table
in this bonded door adhesion room during non-production hours. This could
save over $1,000 a year.
- Provide all employees with stainless steel coffee mugs
with the company logo. This could save over $1,000 per year by reducing the
use of disposable paper cups.
The total estimated cost savings of the above
project is approximately $84,500 a year. CO2 emissions would be reduced by
535 tons. |
