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Demand management opportunities reduced peak demand charges, saving $25,000 per year
130,000 kWh saved per year for each new IMM press purchased as all-electric.
Decreased production cycle time by 5%, yielding additional 500,000 parts per month production.
Assembly Facility (110,000 sq.ft.) Stratford, CT
Saved $28,000 per year in compressed air costs.
60,000 kWh electricity savings from load shifting to new trim compressor.
Custom Anodizing Facility, Watertown, CT
$30,000 per month saved through fuel switching analysis.
Improved part quality checks through lighting retrofits.
Saved $70,000 in fuel oil costs and averted price hikes from petroleum market instability.
Plastic Injection Molder (600,000 sq.ft.) Mukwonago, WI
Conducted energy efficiency audits for industrial and building envelope energy use.
Assessed impacts of chilled-water versus air-cooled chillers on energy use.
AOptimized compressed air systems to increase available capacity and demand management.
AEliminated leaks and extraneous use of air to eliminate the need for additional 200 Hp compressor.
AIdentified substantial energy savings in retrofit of injection molding blanket heaters to electric induction heaters.
AConducted lighting level calculations and illumination measurements for entire facility (shop floor, offices, and other spaces) to determine safe lighting levels and areas for de-lamping.
National Electricity Utility (750,000 sq.ft.) Milan, Italy
Conducted review of Italy’s largest electric utility’s long-range goals for incorporating all environmental costs into current accounting practices.
Lead team of consultants, engineers and management in educational training on specifics of Total Cost Assessment for their power generating processes, and maintenance programs.
Identified pilot projects to gain full management support and build on success for utility wide implementation.
Assembly Operations (80,000 sq.ft.) Stratford, CT
Hired as corporate energy manager to implement energy conservation measures across three facilities in CT over two-year period.
Conservation measures included: air compressor leak analyses, air use reduction, pressure regulation, electricity demand reduction, power factor correction, motor, lighting and heating upgrades, air-side economizer installations, energy management software and metering installations, production machinery retro-fits and replacements and trained floor workers.
Acquired state and utility-based incentives and grants.
Food Manufacturing (800,000 sq.ft.) Middleboro, MA
Developed energy audit for conveyor motors, lighting, and cooling system.
Developed process changes to reduce use of sodium hypochlorite in vessel cleaning operations and reduce washwater volume.
Analyzed impacts of changes on current wastewater treatment and settling system for 2.1 million gpd flow rates.
Conducted feasibility and pilot studies of electronic bio-cide replacement for chemical bio-cide use in process cooling waters.
Proposed adoption of Sustainable Manufacturing practices to corporate officers.
International Nutritional Supplement Company (40,000 sq. ft.) Middletown, CT
Improved energy efficiency of building envelope to decrease HVAC need.
Performed cost/benefit analysis of fuel cells, photovoltaic panels, and ground source heat pumps over conventional HVAC packages.
Incorporated passive solar architectural elements and day lighting to reduce artificial lighting need.
Designed and specified all “green” materials including building envelope materials, flooring, paints, finishes, lighting and furniture for structure.
Large Office Complex (400,000 sq. ft.) Purchase, NY
Energy and Operational maintenance practices audit for commercial office building complex.
Owners desired to pursue LEED Operations & Maintenance certification, requiring the development of Best Practices manuals and policies for all aspects of landscaping, grounds-keeping, tenant fit outs, lighting, HVAC performance, and cleaning of the building interior.
Client was inspired to continue monitoring and tracking building energy performance through EPA Energy Star program due to observed benefits and cost savings.
Film Coating Plant (150,000 sq.ft.) Waltham, MA
Resulted in 25% in coating waste, and energy input following process optimization review on film coating and drying production lines.
Data collection, analysis and report generation for presentation to state, local and corporate officials.
Leather Processing (180,000 sq.ft.) Lynn, MA
10% reduction in heat and energy use achieved following process review of tanning, curing and shaping of cowhides for use in garment manufacturing.
Process evaluation of chromium use, wastewater segregation, conservation and recycling potential.
Developed process modifications to reduce wastewater by 40% and hazardous waste by 25%.