Pressure, Pumps, and Process: Generating Big Energy Savings

Let me share an example of what process efficiency looks like at Husky’s factory in Milton.

Our work, which involves the production of injection molds for the plastics industry, requires an extensive milling and metalwork process. This means that we need ready access to metal working fluids throughout our entire plant. The sophisticated system of pipes and pumps we use is designed to ensure this access – but, until recently, we did not realize that it was wasting a lot of energy.

With the help of an Efficiency Vermont engineer, we devised a way to test the entire system. First, we installed energy sub meters throughout the facility to take precise measurements of energy usage over several weeks. Efficiency Vermont’s analysis of this data showed that we were likely generating a lot more cutting metal working fluid pressure than we needed to – even during times of peak production.

To test this theory, we systematically lowered the pressure on every single pump by plugging up relief valves over the course of several days. Next we lowered the pressure throughout the facility and confirmed that the system could still operate normally – more than meeting our manufacturing needs, while using a lot less energy. This small change, which required no capital investment, is already saving us $10,000 per month, and we saw an immediate drop in our electric bills.