""Am doing great. I have submitted answers below, with implementation dates. We very much appreciate you leading us in the right direction and as you see from the responses below, we have implemented a large amount of your recommendations.
I am also in the process of applying for an Energy Star certification for the plant and will let you know if I need any info. or help.
Thanks again for your help""
- Source: Aspen D'Costa, Operations Manager, Rubbermaid, 08/24/2015
""Thanks for visiting our facility and completing the assessment. We need all the help we can get when it comes to energy reduction.""
- Source: Eric Sucha, Plant Technical Manager, General Mills, 03/11/2014
"This audit has resulted approximately $400,000 annual saving through implementation of recommendations - very close to the estimation in as our report (company recorded 10% of savings out of $4.5M utility costs/year):
"Good Afternoon Dr. Wu,
... I will update you on your findings during your teamâ€™s energy audit at Piramal. It should also be noted that our plant has formed an â€œEnergy Pillar Teamâ€ in an effort to achieve a level 3 status in our â€œOperational Excellenceâ€ program....
AR2. Our XXX furnace was repaired not long after your audit. This furnace is operating more efficiently. Our XXX Furnace is being scheduled for a repair in xxxx.
AR3. I have initiated a quoted project using Amerenâ€™s rebate program. I currently have a proposal to install VFDs on all of our fans before our Corporate office awaiting approval.
AR4. At present our XXX is down for a rebuild and upgrade. I also have an approved project through Amerenâ€™s rebate program to improve control of our compressors. This project includes leak detection and repair of our compressed air system. This project to be completed before November of this year.
AR5. This is a viable suggestion which has yet to be implemented.
AR6. This suggestion is part of the compressed air project mentioned above and will be implemented as funds become available.
AR7. As belts are changed in the course of PMâ€™s, we are re-installing cogged V-belts. Estimate 50% of belts are now cogged.
AR8. Resetting of thermostats for the most part has been accomplished. Problem with keeping unauthorized personnel from changing settings will have to be addressed.
AR9. Photo-eyes have been installed and are working well.
Â· Preliminary data shows electrical saving of about 10% over previous year with just the implemented items.
Â· Our Energy Pillar Team is working to establish data collection with more detail.
Â· I will stay in touch as more data becomes available.
- Source: Dan Hoover, Plant Engineer, Piramal Glass, 06/08/2015
""Hello Bin -
My Maintenance team upgraded the building BMS controls in 2014. In Oct 2014, we tested & Nov refined the control.
The results. In a same time comparison, the site used 814,229 kWh less Jan - May 2013 & 423,564 kWh less than Jan - May 2014.
We implemented 1-3. 4 & 5 were not done."
Update from the company's Sustainability Manager, On Dec 16 2015 Mr. Jeffery Whitford wrote: "I just wanted to reach out to let you know that we're in the very early stages of a major energy efficiency investment. Our business went through a major transition over the past few months as we were acquired by XXXX, Germany. There is an even greater focus on environmental sustainability and investment in energy efficiency. I expect that with this change we will be working on implementing the things you outlined in the coming year or two since we're looking a 3 year program that is probably in the range of a $5 - $15 M investment (coop - wide).
Thank you again ....jw"
- Source: Kurt McClellan, Jeffery Whitford, Environmental and Sustainability Manager, Sigma-Aldrich, 06/08/2015
Please see my responses below, in red. As we discussed over the phone, you are welcome to visit and see the changes we have made. We would be honored to show you and your group our progress.
- Source: Shawn Torrez, Operations Manager - NKC, Arkema, 08/31/2015
Thank you again for a very interesting and productive visit today! ""
- Source: Brad Dickerman, Alsip Improvement Engineer, Arkema, 09/23/2014
""I am interested in a possible intern to focus on energy programs here, would this interest any student? Could be anytime for ?? how long.""
- Source: Jim Westerdale, Facilities Engineer, Maxion Wheels, Sedalia Plant, 08/26/2015
""We had very good feedback from our sister company that you audited earlier!""
- Source: Dan Hunzeker, Operations Manager, General Mills, 03/11/2015
""Hi Dr. Wu,
Thank you for putting this together. We appreciate the time you and your team spent on this. We will review and get back to you with any questions and I will see if I can involve any other sites.
Also feedback from one of the MoIAC student team member (Jeff Hoiday):
"... I first want to thank you for introducing me into the world of energy efficiency and sustainable energy. The opportunity that you (IAC) provided was one that would change my outlook on the ever bearing question of what I want to do when I graduate. You opened the door for me to finally answer that question.""
- Source: Thomas Wagner, Production Manager, Nestle Purina, 06/25/2015
"Forwarded by John Smegal: "Simple feedback. Completely unsolicited. Kudos to Bin. John Smegal (11/29/2011)"
From the company to John Smegal:
"Thank you, I will absolutely keep you posted and as some feedback, I was impressed with the quality of the Versailles, MO energy assessment by the University of Missouri-Columbia compared with the result of some paid assessments at our other locations."
- Source: Ellen Huang, Director, Environmental Affairs, Gates Corporation, 11/29/2011
"" ... thank you for taking the time to follow up. There was a lot of good information in the report that I have budgeted in 2011 to correct.
- Source: Tim Wagner, Plant Operations Manager, Cott Beverages, 10/15/2015
""Dear Dr. Wu,
We appreciate the time and talents that you are dedicating towards the Energy Audit and Recommendations for Ceramo. ...
Vernon L. Kasten, Jr.
President and CEO" "
- Source: Vemon Kasten, Jr., President and CEO, Ceramo, 03/20/2008
""I have mentioned the program to our corporate CEO and of course he has encouraged us to submit the recommendations and start saving money.
Thanks again for all of your assistance. I can assure you that we will be implementing your suggestions this year.
- Source: Buddy Sebastiao, Plant Manager, CMI, 04/22/2008
""Hello again. ... Since your last visit we have considerably reduced our energy consumption by over 25% and have plans in place to reach an 40% or more.
- Source: Erol Artan, 05/09/2009
"On Jul 30, 2013, at 4:12 PM, Joe Kaufman <JKaufman@ofalloncasting.com> wrote:
Dr. Bin Wu
O'Fallon Casting would like to thank Dr. Bin Wu and the IAC team for the Assessment report that helped us to review the recommendations for Compressed Air, Broken Seals on Oven Doors, Insulating all of our steam pipes, heat recovery and replacing our old 1978 Boiler with a new efficient Boiler. These completed recommendations will result in actual cost savings, reduction in CO2 emissions, a reduction in electric and natural gas consumption. You and your team are always welcome at O'Fallon Casting.
Human Resource & Environmental Mgr.
- Source: Joe Kaufman, HR & Environmental Manager, O, 07/30/2013
""Dr. Wu,..., We appreciate everything your team has done for us; . ... (the IAC team) were very professional and thorough during their visit, and we very much appreciate you taking the time to do the audit. .... We wish all of your students luck, and it was an honor to have everyone here at our facility.
- Source: 05/08/2009
It was truly a pleasure to speak with you again. Please find the attached document which demonstrates we have reduced our KWH consumption by 13.9% (while producing more product) since your visit. Thanks again for your assistance and donâ€™t hesitate to call if you need any additional data.
Jason C. Hamblen
Ring Container Technologies
Saint Joseph, MO""
- Source: Jason C. Hamblen, Plant Manager, Ring Container Technologies, 07/20/2011
""Thank you so very much - this is an eye opener in many areas and I'm sure we will be able to use many of the recommendations going forward. We appreciate your willingness to do this for our company."
Also, the following was sent by a IAC student (on 10/6/2015) team member who was involved in this and the other audits:
"I just submitted my application for the IAC certificate request form, and I can not thank you enough for all that you have done for our IAC family the past few years. .. (the) energy efficiency class and being a part of the IAC team have truly been the most rewarding experiences of my college career. As I prepare to graduate in December, I look forward to taking everything ... about energy efficiency and apply it to the real world and be able to make a real impact wherever I end up. Being part of your team has been an amazing experience and more valuable than I can put into words. Thank you again for getting me involved with such a great opportunity. Nick Cain""
- Source: Annette Sachs, Cohen Architectural Woodworking, LLC, 10/08/2015
""Thank you very much for this report. ... I am quite impressed with the comprehensiveness of your study and recommended actions. I will be sure we get our team involved with evaluating this report and taking actions to improve our energy usage performance. ... Thanks again" (March 9, 2016).
"The work you carried out was so relevant and useful, that it has inspired me to initiate a internship program here at our company." (April 6, 2017)."
- Source: Keith Moszczenski, Chief Operating and Fiancial Office, Schlafly , 03/09/2016
Thank You for performing the Energy Audit at Car-Anth Mfg. last year. The audit provided valuable information to Car-Anth while gaining your team experience in performing audits. The Audit made Car-Anth aware of utilities being lost or wasted and therefore dollars being lost or wasted. The audit gave insight into some simple ways to save energy dollars.... Again, Thank You Dr. Wu and the University of Missouri Energy Audit team for the information given to us.""
- Source: Tom Dussoild, CEO, Car-Anth Manufacturing, 03/15/2016
""Your visit and report provided us with motivation and budget information to help us get these done. Thanks you very much for the work you've done.""
- Source: Rod Colhaun, Plant Manager, 03/29/2017
""Such a wonderful opportunity - you can use me as a reference anytime!"
Thank you for the follow up to the audit you and the students performed last year. I found the observations very insightful and relevant to our manufacturing operation. It was extremely helpful to learn how to quantify the savings. It is easy to overlook and avoid making the investments until you place a value on what it costs you in energy costs. Though we are unable to implement some of the items we've taken the first steps with trading out the light fixtures throughout the facility as suggested by your audit team.
- Source: Drew Dubray, Plant Manager, Takara Belmont, 03/29/2017
"The report looks great! Very detailed and payback calculations make it easy for our team to prioritize. We are planning to discuss it tomorrow in our weekly management meeting and come up with an action plan to start getting some of the improvements underway. I will let you know how things progress. It has been a real pleasure working with you and your team. "
- Source: Duane Clonts , Maintenance Manager, 05/19/2017
"Positronics Industries, Inc, has greatly benefited from the relationship that has developed with the IAC. The energy audit and assessment in which the IAC performed at our three Missouri facilities is part of our continuous improvement process of reducing and maximizing the energy used at these facilities. The audits have made us look at the feasibility of installing LED lighting, energy efficiency motors, and evaluating HVAC systems just to mention a few areas. The resulting cost savings can then be invested into the company. Having a relationship with the IAC provides Positronics Industries an additional partner in the journey down the path of sustainability and environmental stewardship. Another benefit is the information and techniques from the energy audits performed can be used to assess our other global divisions. This is a win-win situation. "
- Source: Scott Foley, Project Manager, 05/13/2016
"This is a very comprehensive energy report. Very well stated through careful engineering calculations. I am glad to see that all data used were true and within range. Savings calculated are realistic and initial cost were low. Bottom line is, I like your approach of evaluating what we have and figuring out how to manage the equipment to yield higher throughput in relation to operating cost before any expensive upgrade implementations. (by Khanna: this comment relates to the battery cooling AR #9, I had suggested that they should first conduct an experiment on a small table that mimics their larger scale production)
I truly appreciate the effort and hard work of you and your team. I assure you that most of these, if not all, recommendations will be implemented in our facility and perhaps to all JCI plant across NA. Moving forward, my team will develop an action plan to start implementing these recommendations. I will definitely call you if we have some questions.
Thanks for the help. Please extent my appreciation to your team.
- Source: Greg Gelbolinga, Engineer III/CI, 07/31/2017
"The audit process is valuable to help understand the highest areas of benefit and to allow us to get a outside perspective on the projects we should focus on. We have been able to start projects earlier by having the energy savings to justify the projects. "
- Source: Glen Kloeppel, Project Engineer, 08/09/2017
"In relation to our audit, we also recommended to the company for a MoIAC student internship to follow up with the implementation of the recommendations.
As a result, Austin Laramie, a MoIAC student and at the time also enrolled in Bin Wu’s “Industrial Energy Efficiency and Management (MU IMSE 4580)” class, was employed during the summer by the company:
According to the company: “ (the MoIAC student) helped to go through the details of every recommendation on the list. This worked great!”
From the student (Sep 25, 2017):
The IAC program I was involved in was fantastic experience in a very important area of Industrial Engineering. Learning how to directly identify improvement areas in energy efficiency in a factory was great knowledge that can be used generally wherever my degree takes me in industry. Any time I walk into a new manufacturing facility I can immediately recognize energy that is being wasted or can be more efficiently utilized in the plant. Helping organize reports on the recommendations were also great practical application to showing upper-level management how the energy-savings investment is worth while based on a simple payback period from predicted utility bill savings.
Your classes helped me grasp a deeper connection with how all of the units in energy efficiency come together to make calculations a breeze. Before taking your class I was clueless on the difference between a kilowatt and a lumen but now I could present these to a class of my own from all the practical experience and practice.
Lastly, I can't thank you enough for helping me connect with Hunter Engineering Company which gave me a paid summer internship experience focusing directly on the subjects we talked about in class and did in IAC. From the start of the summer, I had no problems talking to my boss about lighting, air-conditioning, pneumatic, or other systems that was costing the company thousands of dollars in utility bills per year. I had the chance to represent multiple options for energy-saving improvements to their facility and exactly how much they were projected to save from each opportunity.
Overall, the IAC program, your classes, and my internship with Hunter Engineering have all dramatically helped my professional industrial engineering skills to make me a better asset for companies in the future. I cannot thank you enough for your patience and believing in all my potential. Hope to see you soon,
Industrial & Manufacturing Systems Engineering
University of Missouri - Columbia""
- Source: Tom Meyer, Vice President of Engineering & Materials, Hunter Engineering, 09/13/2017
"Thank you, Dr. Khanna, it was a pleasure for our Mascoutah team to learn the techniques of energy assessment from you."
- Source: Bhuvnesh Joshi, Energy Engineer, Legrand, 01/03/2018
"Working with Sanjeev’s team was a delight. They were knowledgeable, professional and asked great questions to understand our process completely before generating a report with suggestions. The report highlighted some improvement areas that we had not thought of yet which was fantastic. Thank you very much for your time to help us continuously improve our energy reduction plans."
- Source: Christina Stage, Lean Manager, Silgan Plastic Food Containers, 01/11/2018
We are very appreciative of your work with the students on the audit. I thought the team did a great job!
We are actively putting together the financing packages for several of the recommendations. Many of the projects are part of our overall sustainability initiative on campus.
We would love to continue the relationship as we are always trying to figure out how to do what we do better and more efficiency. If you see opportunities in the future to work with together, will you reach out?
- Source: Peter Hofherr, Chief Executive Officer, St. James Winery, 04/06/2018
"Thank you and your professional students for the collaborative time auditing and understanding our facility which provided excellent assessment recommendations in which to reduce operating cost and the subsequent CO2 emissions. I would be interested in a follow up that shows expected annual savings from what we have done or expect to complete by year end."
- Source: Vince Gochenauer, Plant Manager, Silgan Containers, 06/20/2018
This audit is very well done. Not only does it provide Dean Foods with sustainability projects and the savings calculations use for project justification, it also provided your students with real world hands-on experience.
I support the O’Fallon plant from a corporate engineering function, so when Randy presented your idea to perform the audit I thought it was a great fit with our sustainability objectives. Dean Foods, like many organizations today, is being asked to dig deeper for sustainability and cost savings projects, so this audit will allow us to fill the pipeline.
Randy and I will get together to look over the projects and discuss possible timelines for completion.
Thanks again for teams work.
- Source: Jerry Brunner, Director, Regional Engineering - North Region, Dean Foods, 08/30/2018