Square D companies such as Juno Lighting Group and TAC, LLC, initiate energy optimization for it’s own plants and facilities, with an ambitious goal of reducing energy consumption per employee by 10 percent from 2004 to 2008.

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Market growth and frequent product innovations were forcing the facility personnel at Smith and Nephew's Memphis plant to struggle to keep up with the demand for changes in the manufacturing processes. Without a good monitoring system to provide an accurate picture of loading, electricians struggled to determine if particular circuits could handle new loads. After installing a PowerLogic system, the staff soon had accurate peak demand data that allowed them to add new loads to existing circuits and avoid a $2 million expansion.

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A PowerLogic system installed to help keep an eye on costs helps uncover costly errors in the plants utility metering. After reviewing data from PowerLogic System Manager Software, a company executive discovered a major discrepancy between system manager reported data and the utility bill in regards to power factor. Further investigation revealed an uncalibrated utility meter resulting in a $250K credit for past power factor penalty charges.

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Like many plant engineers, Dave Tracy and Jim Vyuerberg of Pharmacia Corporation vividly remember the times when clipboards and shoe leather were the key components in monitoring energy consumption. They and their colleagues had to trek all over the plant to scribble down power meter data, then manually enter it into a spreadsheet program. At Pharmacia?s Kalamazoo, Mich. plant, however, all that trekking and scribbling has been replaced by a power management system that saves time, cuts costs and preserves uptime.

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A large production facility in the mid-west is required by the Environmental Protection Agency (EPA) to monitor the emissions of their stacks. They looked to Schneider Electric?s local Square D team for a solution, which revealed that the PowerLogic system is capable of monitoring gas emissions, meeting the data acquisition requirements and could be retrofit for substantially less than the previous SCADA solution!

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Recently, one of our customers provided an interesting anecdote on how the PowerLogic system helped them pre-empt a potentially significant energy waste at their plant.

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