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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
Crystal Cabinet Works, Inc.
Crystal Cabinet Works, Inc.
• 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
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
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
Air Compressor Savings
Air Compressor Savings
Air Compressor Savings
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
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