Energy Efficiency at Crystal Cabinet Works, Inc.

Nick Weis Director of Engineering & Technology

Crystal Cabinet Works, Inc.

Energy Savings $$$$

Saving Energy… reduces $$$$ of doing business

Company background

Some examples over past 6 years

Results

Lessons learned


• Established 1947 Crystal, MN 60th Anniversary

• Family owned (3rd generation)

• 3 Mfg. locations 350,000 sqft. (Princeton & Sauk Rapids)

• Mfg. med.- high end residential and commercial cabinetry

• 25%Custom (“You can draw it, We can build it”)

• Sell through a nation wide dealer network• 450 employees

Plant Lighting Retrofit

Lighting Benefits

High bay 4.4 kwh/day

Fluorescent 2.1 kwh/day (T-8)

Est. 7 mo. payback, Actual 3 mo.

Investment $110,000 before rebate

Rebate through Utility Companies

Side Benefits:

Consistent light spectrum

Increased foot candles

Employees… easy on the eyes

Heat Recovery Savings

Heat Recovery Savings

Investment $75,000 before rebate

Payback 9 months

Custom rebate through N. Gas Supplier

Free heat (wasted before)

Sauk Rapids Boiler

• 98 hp wood fired boiler• Fully automatic stoker system• In floor radiant heat• 2 heat exchangers Painting operations

supplemented Nat. Gas • Silo storage system (summer to winter)

Cost Benefit Wood Heat

• Annual savings over $75,000• Annual N. Gas $.58 /sqft Sauk Rapids

facility• Annual N. Gas $1.25 /sqft Princeton

facility• N. Gas $/cab. 50% less Sauk Rapids

Air Compressor Savings


Old Compressor ran full load 22 hrs./day

New Compressor mod. Based on load

Payback 1.5 yrs. ($12,732/yr.)

Replaced old Air Comp. $5,383/yr.

Outside Air Comp. Consultant…Leaks, inefficient Air Comp. (utility sponsored)

Repaired air leaks $2,387/yr. savings investment $1,118

Savings on maintenance costs

Energy Saving Motor Controls

High efficient motors

Soft start controls (reduce peak load)

Variable Frequency Drives (VFD’s)

On/off controls

Glue gun timers

Photo eyes

Energy Saving Motor Controls

Photo Eyes

Roof Repair

Roof Repair

Leaky roof… damaged some products

Added R16 insulation value

Heat loss in winter

Employee moral

Cooler in Summer

Supply Chain Savings

Smart Way® Trucking

Ship product by rail

Receiving product by rail through distributor

Combine shipping/receiving w/local mfg.

“Last-Mile” delivery process

Purchasing more local mtls.

Materials RecycledSUMMARY

in lbs. per calendar year

2006 2007 2008

Cardboard/Paper 193,825 222,160 199,785

Scrap Metal 6,552 7,840 22,185

Packaging Plastic 685 587 498

Going GreenWood ProductsForest CertificationEnv. Pref. Prod.Kitchen… ESPGreen FinishesLEED Products

Other Energy Savers $$$$

Regular PM on HVAC units

Defect reduction 12-75% through Lean Mfg. applications….$$$$$

Heat recovery re-circulate curing ovens

New Equipment Energy Eff.

Fuel efficient company vehicles

Turn off equipment during lunch

Lessons Learned

Accept that cheap fuels won’t be back

Involve your utility companies

Don’t tackle all at once…have a plan

Involve your key employees

Measurements before/after

Take action

Energy Efficiency at Crystal Cabinet Works, Inc.

Technology

Transcript of Energy Efficiency at Crystal Cabinet Works, Inc.