Compressor upgrade drives immediate savings, fast … · ABC said, ‘wow, that was easy, what do we do next?’” ABC Climate Control ... advantage of variable frequency drive technology

ABC Climate Control Systems Inc. (ABC) manufactures plastic moulded

components for automotive ventilation systems.

After meeting with Toronto Hydro to review opportunities for saving electricity in

its plant, ABC was provided with the services of a Roving Energy Manager. His

tasks included monitoring the plant’s current electricity consumption trends,

identifying energy use by equipment and then prioritizing savings opportunities.

The fi rst project optimized the compressor plant and included replacing two old

100 hp and 150 hp compressors with one new 250 hp variable frequency drive

(VFD) compressor.

Operations Manager Robert Smyth is thrilled with the result and the payback

period. “It was fl awless working with Toronto Hydro. It was so well-executed that

ABC said, ‘wow, that was easy, what do we do next?’”

ABC Climate Control Systems Inc.

PROJECT STATISTICS

ABC Climate Control Systems Inc.

optimized their compressor plant

by replacing a 100 hp and 150 hp

compressor with a new 250hp

unit equipped with a variable

frequency drive.

Total project cost: $228,150

Demand savings: 130 kW

Energy savings: 282,000 kWh

Electricity savings: $42,768/yr.

Incentive: $105,754

Payback with incentive: 2.5 years

CASE STUDY

July 2014

Compressor upgrade drives immediate savings, fast payback

ABOVE: Toronto Hydro’s Mary Byrne presents an Energy Conservation Leadership plaque to Robert Smyth.

RIGHT: Neil Parker, Roving Energy Manager Dilesh Thurai, Robert Smyth

For more information or to apply for saveONenergy programs:

416.542.3388

[email protected]

torontohydro.com/industrial

VFDs are the key to compressor savings

ABC’s new compressor takes

advantage of variable frequency drive

technology to control the speed of the

motor. The VFD varies the speed of the

compressor motor to match supply

needs so that the unit is not cycling and

operating ineffi ciently. That means the

compressor uses only as much electricity

as it needs for the immediate task.

In older compressors, the fi xed-speed

motor cycles to maintain pressure at a

fi xed speed. This is like travelling in

your car at two speeds – stopped and

100 km/hour.

Reliability is critical in a busy environment

ABC’s new compressor runs their

pneumatic fi xtures and blow-moulding

machine. Both are essential to its

24/6 operations.

Smyth said, “We had a lot of down

time and higher operational costs with

our old compressors. The new one

reduces these costs and is digitally

controlled, which makes it much easier

for our maintenance staff.”

No-cost Roving Energy Manager drove the project

Both Neil Parker, ABC’s Controller, and

Robert Smyth sing the praises of

Roving Energy Manager, Dilesh Thurai.

Smyth said, “Dilesh did a lot of leg

work, pulled together the data and

fi lled out the incentive applications.

He’s done all that and we’re reaping

the rewards.”

Motors and chillers are next for energy savings

ABC is currently evaluating the

motors in its production lines and

chilling system to identify energy

conservation opportunities.

Additionally, fi ve other ABC plants in the

Toronto area are now working with

Roving Energy Managers to fi nd savings.

“We constantly measure our effi ciency by kilowatt hours of electricity per pound of material we create. We set targets and look to reduce costs.”Robert Smyth, Operations Manager, ABC Climate Control Systems Inc.

Toronto Hydro Incentive Programs

Toronto Hydro offers

saveONenergy programs to

help industrial customers

improve their energy effi ciency.

The programs provide fi nancial

incentives and technical

expertise which may include the

services of a Roving Energy

Manager at no cost to you.

Look for energy-saving

opportunities in your machinery,

systems and processes.

Conservation can deliver

immediate savings and an

excellent return on investment.

Contact us today to get started.

Note: Incentive amounts shown include applicable taxes. Subject to additional terms and

conditions found at torontohydro.com/business. Subject to change without notice. Programs

are funded by the Ontario Power Authority and offered by Toronto Hydro. Project results have been

verifi ed by Toronto Hydro. OMOffi cial Mark of the Ontario Power Authority. Used under licence. ® A

registered trademark of Toronto Hydro Corporation used under licence. “Toronto Hydro” means

Toronto Hydro-Electric System Limited.

LEFT: Toronto Hydro’s Mary Byrne (far left) and Don Connolly (far right) present the incentive cheque to ABC’s Robert Smyth and Clay Birkett