Upgraded 2 large Paper Mills' plant lighting, and installed VFD’s on process cooling & pulp systems. Metering was included in each project for monitoring and verifying the savings (M&V).
Upgraded 6 MSF plant lighting to LED, adding new centralized UPS systems for emergency lighting with new power supply infrastructure. Monitoring and verifying the savings (M&V) was accomplished by installing new metering.
Upgraded Lighting, Paint Shop Controls and HVAC at several 2.5 - 4 MSF Auto Assembly Plants. New Energy Metering system was provided for monitoring and verifying the savings (M&V).
ESPC–New Air Plant
Installed an 1800HP new compressed air plant, converted a portion of the plant lighting to LED, and installed variable speed drives on mill motor room makeup air fans to meet room temperature and pressure requirements.
Upgrades included lighting retrofits, VFD’s on process cooling systems, Chiller replacement, EMS & HVAC improvements at various Auto Assembly Plants. Metering was included for monitoring and verifying the savings (M&V).
Installed variable frequency drives and level transmitters for zone level control and modified PLC program to hydraulically and thermally balance their regenerative pasteurizers and minimizing and optimizing energy and water consumption.
MUTT Software (KPI Tracker)
Developed a software tool for all global sites to easily create an annual Sankey diagram of energy and water use and intensities. Master Utility Tracking Tool or the “MUTT” tool gives pet food sites an annual performance check to focus their continuous improvement efforts toward the largest performance gaps.
Flash Steam Recovery
Process heating optimization and addition of a new condensate receiver and flash steam recovery system to preheat the makeup water to the process and prevent the loss of heat energy through the vapor exhaust.
Fryer Energy Recovery System
Fryer Exhaust Energy Recovery System upgrades and redesign were needed after process changes that eliminated original heat sinks. Designed new heat sink integration plan to fully utilize energy recovery system and minimize water footprint at the same time.
Process Cooling Optimization
Changed a single-step cooling process using chilled process water to a two-stage process using ambient temperature process water in stage 1 (to make hot water) and glycol in stage 2. Modified control algorithm for control of new process, adding the ability to adjust the stage 1 performance based on maximum efficiency or hot water volume requirements.
Portfolio wide LED Retrofit
Retrofitted all NA facilities interior and exterior lighting to LED while upgrading to sanitary fixtures for improved food safety in manufacturing areas.
VFD Retrofit & NH3 Controls
Retrofitted trim NH3 refrigeration compressor and condenser fans to VFD, then upgraded system controls to allow optimized sequencing, floating head pressure control, auto start/stop sequencing.
Boiler & NH3 System Upgrades
Retrofitted burner and boiler controls to improve efficiency. Replaced NH3 controls with new AB PLC, and implemented floating head pressure control, suction pressure reset, auto sequencing, and auto start/stop scheduling
New Boiler Plant
Executed Design/Build of (2) new direct contact hot water boilers, with condensing stack economizers. Eliminated the use of steam boilers that were near end of life.
Air Compressor Cooling Upgrade
Replaced open-loop cooling towers for two centrifugal and two screw air compressors with a closed-loop glycol cooling loop integrated into an alternative and existing cooling system with available capacity. Project avoided significant capital renewal costs through cross system integration and eliminated maintenance cost with open loop cooling.
Compressed Air Controls
Installed additional compressed air storage to reduce the impact of demand spikes and installed a new PLC master control system to optimize the operation of all the compressed air equipment.
Developed a multi-year capital investment strategy to achieve a 5% energy savings for the site. Identified over 20 cost saving projects and prioritized them by year to achieve glide slope performance to meet corporate goals.
Process Chiller Plant Renewal
Redesigned & replaced 30+ year old constant speed chillers, with a new highly efficient, variable speed chiller and with a conversion to a variable primary chilled water distribution design.
Rolling Mill Spray Fume Exhaust Fan VSD’s
Installed variable speed drives on the rolling mill spray hood exhaust fans to reduce fan speed whenever metal is not being rolled, which was over 40% of the roll processing time.
Developed a multi-year capital investment strategy to achieve a 5% energy savings for the site. Identified and developed 20 cost saving projects and prioritized them by year to achieve glide slope performance over 3 years.
Upgraded the 1.1M SF Hospital campus with new interior and exterior LED lighting, without impact to patient operations, and captured available rebates from LADWP.
Upgraded this  Hospital System with new interior and exterior LED lighting, while in operation, and captured all available rebates from MidAmerican Energy.
Retrofitted  larges sites in Central and Latin America to LED lighting, with selective high ROI lighting re-design and smart control upgrades.
Upgraded this  Hospital System with new interior and exterior LED lighting and captured rebates from NYSERDA.
N2 Self Generation
Turnkey installation of on-site nitrogen (N2) PSA generation plant, used for product sterilization, eliminating liquid nitrogen supplied from 700 miles away by sea. New N2 system coupled with the sites’ compressed air plant to provide air plant asset upgrades and redundancy.
Implemented new LED lighting and control solutions for Mt Sinai West Hospital building and the New York Eye and Ear building in New York City.
Tri-Gen Heat Recovery Optimization
Modeled 2 existing 5MW Tri-gen systems unlocking operational cost optimization strategies. Provided turnkey delivery of controls improvements and enhancements measures, such as redirected heat dumped through the system radiator to the warehouse for free winter heating.
MEP Design - New Cleanroom
When traditional construction methods proved ineffective for the project budget and timeline, E4E stepped in to help this client implement a modular cleanroom solution for the new 170k SF ISO-8 facility. E4E delivered the greenfield MEP design on-budget and on-time.
Cleanroom Energy Recovery
Installed a glycol “run around” loop with new air coils to capture heat from laboratory and clean room exhaust and use it to preheat HVAC makeup air.
Chilled Water Plant Optimization
Installed a new variable speed jockey chiller for winter loads and moved the process chilled water loads from old, inefficient chillers to the more efficient variable speed HVAC chillers.
Renewable Energy Viability Study
Evaluated cogeneration, wind, and solar PV generation configurations options for  sites and recommended best size and combinations of assets to achieve optimal ROI.
Compressed Air Optimization
Installed and re-commissioned compressed air controls to reduce system pressures to the campus based on minimum equipment requirements, with pressure resets for idle production times.
Dust Collector VFD Conversion
Installed VFD’s on process dust collection exhaust fans to reduce fan speed during idle periods and when individual exhaust points are not needed and isolated. Added VFD controls to makeup air units and balanced makeup air with exhaust volume changes through room pressure control.
Compressed Air Optimization
Performed complete compressed air system assessments and leak survey at 3 Chicago area sites. E4E, as the qualified service provider, fixed all leaks and provided various upgrades (sequencing controls, storage, and heat recovery) utilizing the utility’s rebate program.
R22 Phase Out Strategy
Developed R-22 asset renewal/retrofit strategy for 6 brine process chiller systems, then provided project design services for a multi-year, R-22 phase-out program, while incorporating capacity increases as part of a debottlenecking project.