Caterpillar - Integrated Manufacturing Operations Division
East Peoria, Illinois
Intern: Alex Dunker
Southern Illinois University at Edwardsville
Caterpillar's manufacturing complex in East Peoria is the home to the company's track-type tractors and pipelayers – machines that are used in infrastructure and mining projects in the U.S. and across the world. The complex covers approximately 700 acres, just east of the Illinois River. The intern project focused on several energy and water projects related to lighting, domestic water, daylighting and hand dryers.
Results:
Completed projects and recommendations made by the intern include:
- Identified billing errors in the municipal water use at two buildings. The compound water meters were read incorrectly, leading to an overestimate of water use, totaling 1-2 million gallons per billing period over 5 years. Upon rectification of the irregularity, accurate readings will become available again, and an adjustment in the water bill will amount to over $217,000.
- Identified several processes within Building LL that were using municipal water instead of mill water for process operations. Converting to mill water reduced domestic water usage by 6 million gallons a year, saving approximately $47,000.
- Recommended several lighting upgrades in three buildings that have the potential to save a total of $610,000 a year.
- Recommended uncovering the south and east facing windows of Building NN to allow daylighting. Approximately 30 fixtures could be daylight-controlled for a cost savings of $1,000 a year. The savings do not take into account worker productivity, which may increase with improved lighting and interaction with the outside environment.
- Recommended the installation of Xlerator high velocity hand dryers. These dryers would reduce paper towel wasteApproximately 30 dryers could be installed, saving $400 a year each. Cost savings would total $12,000, with a payback period of one year.
- Re-evaluated a motor study done by the 2008 IEPA intern. The study recommended the use of variable frequency ddrive units with a select range of new motor installations. These upgrades could be implemented over time., The savings would total over $150,000 a year, with less than 3-year payback.
- Mapped recycling stations throughout all IMOD facilities to identify ways to make the collection effort more efficient. Fabricated labels for bottle recycle bins that advised users to remove lids from bottles before discarding. This allows for better compacting and less recyclable material being diverted to the landfill.
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