Ford Van Dyke 2081 CIS EO Compressed Air 05 0046 136677 7
User Manual: 2081
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Performance
Spotlight
Ford Van Dyke:
Compressed Air Management Program Leads to
Improvements that Reduce Energy Consumption at an
Automotive Transmission Plant
Project Summary
Between 2000 and 2003, staff at the Ford Van Dyke Transmission Plant (VDTP)
in Sterling Heights, Michigan, increased the ef ciency of the plantʼs compressed
air system. The plant has a rigorous compressed air management program that
enables staff to maintain the compressed air systemʼs ef ciency and identify
potential opportunities to reduce the amount of energy that the system consumes.
After VDTP staff identi ed opportunities for system improvements, a staff member
from a U.S. Department of Energy (DOE) Allied Partner, Scales Air Compressor
Corporation, helped to clarify some of the opportunities in a brief walk-through.
Along with some planned equipment upgrades, improvement measures were
implemented to improve the compressed air systemʼs performance, saving energy
and improving production. Measures that were implemented between 2000 and
2003 have resulted in energy savings of more than 1 million kWh for compressed
air, and energy and maintenance cost savings of $165,000. The total cost of the
planned upgrades and other measures was $336,000, yielding a 2-year simple
payback.
Plant/Project Background
In operation since 1968, the VDTP is a 1.9-million-square-foot automotive
transmission plant that produces more than 9 million car and truck transmission
components annually. Compressed air is important at the VDTP for many
pneumatic tools, stamping equipment, blow-off applications, and counterbalance
cylinders. Plant personnel consulted with Scales Air Compressor Corporation to
assess the system as part of a corporate initiative to improve energy ef ciency. That
review con rmed the bene ts of eliminating unnecessary blow-off applications and
air leaks as well as moisture carry-over, which resulted from a poorly functioning
dryer that was near the end of its useful life and scheduled for replacement.
After the review, VDTP personnel moved forward with their anticipated compressed
air system improvements. They began by replacing the ineffective dryer and
conducting an aggressive and ongoing leak repair campaign. Plant personnel then
eliminated the unnecessary blow-off applications and installed ow and dew point
meters to accurately gauge the volume and quality of the air being generated. These
measures helped to reduce pressure drop in the system, allowing the compressor
discharge pressure to be lowered from 108 to 98 pounds per square inch gauge.
Bene ts
• Saves $165,000 annually
• Reduces annual energy
consumption by more than
1 million kWh
• Increases production throughput
Industrial Technologies Program
Proven Tools and Practices to
Increase Industrial System Energy Ef ciency
Applications
Almost any industrial facility can
bene t from having a compressed
air management program. In
many cases, projects identi ed
and implemented under such
a program will reduce energy
consumption and generate
savings. In addition, these
projects can help to improve
production, reduce downtime,
and trim maintenance costs.
Proven Tools and Practices to
Increase Industrial System Energy Ef ciency
BestPractices is part of the Industrial
Technologies Program, and it supports
the Industries of the Future strategy.
This strategy helps the country’s
most energy-intensive industries
improve their competitiveness.
BestPractices brings together emerging
technologies and energy-management
best practices to help companies
begin improving energy efciency,
environmental performance,
and productivity right now.
BestPractices emphasizes plant
systems, where signicant efciency
improvements and savings can be
achieved. Industry gains easy access
to near-term and long-term solutions
for improving the performance of
motor, steam, compressed air, and
process heating systems. In addition,
the Industrial Assessment Centers
provide comprehensive industrial
energy evaluations to small- and
medium-size manufacturers.
A Strong Energy Portfolio
for a Strong America
Energy efciency and clean, renewable
energy will mean a stronger economy,
a cleaner environment, and greater
energy independence for America.
Working with a wide array of state,
community, industry, and university
partners, the U.S. Department
of Energy’s Ofce of Energy Efciency
and Renewable Energy invests
in a diverse portfolio of energy
technologies.
FOR ADDITIONAL INFORMATION,
PLEASE CONTACT:
EERE Information Center
1-877-EERE-INF
(1-877-337-3463)
www.eere.energy.gov
Visit our home page at
www.eere.energy.gov/industry
Industrial Technologies Program
Energy Efciency and Renewable Energy
U.S. Department of Energy
Washington, DC 20585-0121
Results
The continuing optimization of the VDTPʼs compressed air system is yielding
energy and maintenance cost savings while improving production. Total
annual energy savings for compressed air are 1,075,000 kWh, and annual
energy and maintenance costs are lower by $165,000. Even more important,
product quality and process control have improved. Between 2000 and 2003,
the plantʼs compressed air costs per unit of production declined by 18% and
production increased by 2% as a result of the greater reliability and better control
of compressed air to processes. The total cost of the improvement measures
implemented during that time was $336,000, which results in a simple payback of
just over 2 years.
Lessons Learned
A rigorous compressed air management program that takes into account how
various end-use applications within a plant use compressed air can lead to more
efcient system performance and lower energy costs. An independent review
validated the Ford VDTP staffʼs assumptions about their compressed air systemʼs
energy consumption patterns and what was necessary to enhance the systemʼs
energy efciency. Their resulting actions did more than just save energy; they also
strengthened an institutionalized management program that increased awareness
about the systemʼs energy consumption, and this led to further improvements.
In addition, they realized that trending compressed air use against production
levels can be very useful in documenting system performance. Compressed air
management programs such as this one can easily be implemented in industrial
facilities that use compressed air.
Project Partners
Ford Motor Company
Sterling Heights, MI
Scales Air Compressor
Corporation
Carle Place, NY
Partner Prole
William Scales, president of Scales Air Compressor Corporation, is an
internationally recognized expert in compressed air systems. Over the
last 40 years, he has visited more than 5,000 facilities and audited
hundreds of compressed air systems throughout the world for a
wide variety of industrial companies. He is a Qualied Instructor for
the Compressed Air Challenge® (CAC) Fundamentals and Advanced
Management training and was a member of the core group that de-
veloped this training. In addition, his company is a DOE Allied Partner.
CAC Instructors
The CAC qualies instructors who are trained, certied experts in
the use of compressed air systems. They are dedicated to providing
industrial end-users with strategies they can implement immediately
to improve the efciency and reduce the costs associated with
compressed air systems in their plants.
William Scales
DOE/GO-102005-2081
May 2005
