Energy Edge Solutions

Plymouth Printing



Printing Facility Case Study

75 year old leading printer for healthcare markets. Two facilities totally 100,000 square feet. Significant equipment loads. Top of the line printing and finishing equipment.

Business Situation

The Plymouth Printing plant runs multiple shifts throughout the year. The lighting system was comprised primarily of linear fluorescent; much of it specialty lighting typical of this type of facility. Two dozen roof top units condition the office, production and warehouse space in the facility and the production process utilizes a multitude of different motors of various horsepower and duty cycles. Plymouth Printing’s energy bills represented a large percentage of operating costs and the company was looking for ways to prudently reduce overhead.

Energy Edge’s combination of engineering approaches and technologies, along with your expertise, is a fine testimonial to your firm’s work, dedication and commitment.

Len Dillon | Plymouth Printing Director of Finance

Process

As a first step Energy Edge Solutions (EES) conducted a comprehensive whole building investment-grade energy audit and engineering study of Plymouth Printing’s facilities. The audit included an intense review of the following areas:

Utility Bills: EES reviewed the previous 12 months of utility data for the facility.

Designs: EES reviewed all available electrical one line and mechanical drawings.

Facility Energy Behavior: EES reviewed with the customer the current energy behavior of the staff including temperature set points, setting back temperatures when the facility is closed, turning off lights, office equipment, etc. after hours.

Building Envelope: EES checked weather stripping, insulation, open doors and areas around frequently trafficked areas, etc.

Lighting Systems: EES reviewed the current lighting systems to determine if the most efficient lighting options were being used and if occupancy sensors, timers and dimmers had been placed into operation. EES also looked for areas that were over lit and areas that could take advantage of natural sunlight.

Heating, Ventilation and Cooling Systems: EES looked at the HVAC/R systems to determine operating efficiency, maintenance schedules, filter replacement frequency, age, and upgrade and treatment options.

Motors and Equipment: EES itemized all electrical loads across the facility (including HVAC, production and refrigeration equipment) and their respective run times. Actual electrical measurements such as amperage, voltage, THD%, power factor, etc were taken at all loads as well as at the main. Load, duty cycles, operating efficiency, age, replacement and treatment options, etc. were all determined.

Solution

Energy Energy Edge Solutions (EES) recommended a whole facility approach to energy cost reduction to significantly reduce the customer’s expenses. Based on EETC’s preliminary analysis, Plymouth Printing was guaranteed a minimum kWh reduction of 8.12% and a maximum project payback of 32 months. After completion of an in-depth engineering study and project design, EES guaranteed to reduce Plymouth Printing’s energy consumption by 8.64% with a payback on the turnkey project of 30 months or less.

Benefits

EETC measures the success of all projects in accord with the International Performance Measurement and Verification Protocol, Option C (www.IPMVP.org) as approved by the U.S. Department of Energy. EES compiles a statistical measurement and verification report quarterly for customers which includes utility bill analysis, base and verification period comparison, building simulation/ modeling, inclusion of all factors of influence, statistical correlation, regression analysis, etc. After completion of the turnkey project, Plymouth Printing has been enjoying an average annual kWh reduction of 9.88%. The turnkey project paid for itself in less than 26 months which translates to a straight line return on investment of 46% for the customer.

Products and Services Recommended and/or Employed

  • Variable Frequency Drives
  • Ultrasonic air leak detection and remediation
  • Lighting retrofit
  • Anti-compressor short cycling for air conditioning systems
  • Oil supplementation for increased cooling capacity of air conditioning
  • Power quality improvements
  • Electrical sine wave modification
  • Energy management system
  • Anti-compressor short cycling
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