January 28, 2010
Customer Profile
Bostik is a world leader in adhesive and sealant manufacturing. In 2008, the company employed 5,000 people across 48 manufacturing sites and 12 research centers, and generated nearly $2 billion in business. In Calhoun, Ga., the company operates a 23-employee facility.
Situation
With such an expansive and diverse company, it made sense that Bostik’s parent company would mandate an energy reduction program to keep costs under control. While the Calhoun facility operates on a smaller scale, it still needed to use energy efficiently.
Solution
Ray Davis, plant manager, and Dan Conetta, production manager, selected Georgia Tech’s Enterprise Innovation Institute (EI2) to help implement their energy reduction program because of its expertise in energy reduction and lean manufacturing. An EI2 energy specialist visited the Calhoun facility to identify areas where energy improvement could be realized, communicated industry best practices and provided advice and consultation on the procurement of diagnostic tools for energy reduction purposes. She made a number of recommendations for Bostik, including utilizing more efficient fluorescent bulbs, reducing peak load by staggering equipment startup, relocating the air compressor intake from indoors to outdoors, discontinuing the unnecessary use of compressed air, reducing boiler blow-down in the summer, recovering steam condensate and properly insulating the boiler and steam piping.
Results
- Reduced its energy consumption by an estimated 56 percent, saving $40,000
- Cultural shift towards energy reduction awareness and a reduced corporate energy footprint
In addition, employees have expanded their knowledge of energy reduction practices and Georgia Tech continues to be a resource to facilitate continuing education in energy reduction. As part of the U.S. Department of Energy’s Industrial Assessment Center (IAC) program, Georgia Tech can provide energy, waste and productivity assessments at no charge to small- and mid-sized manufacturers.
Testimonial
“Although the intent was not for Calhoun to be a model or pilot plant, many of the best practices which originated at this facility were leveraged and other facilities benefited from our experience with Georgia Tech. Additionally, some of the other Bostik facilities approached universities in their areas that are part of the same national energy reduction partnership and had energy audits conducted,” said Dan Conetta, production manager.
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