When we talk about energy, the focus is usually on technology and technical solutions. However, energy behavior is gaining more attention as a “hot topic” in energy innovation. Until recently, in my experience as an ISO 50001 auditor of energy management systems, I found that in many organizations consideration of the role of energy behavior in energy savings efforts has been confined to “Turn off the lights when you leave” stickers on light switches or “Close the door” signage, and the like.

What has been lacking is a focused and structured approach to achieving and sustaining energy behavior change. But it appears this is beginning to change as organizations look for new low-cost energy opportunities in the face of increasingly constrained capital budgets; as more case studies are published on the application of social marketing and psychology to achieving sustainable behavior; and as organizations adopt and benefit from implementation of the ISO 50001 standard for energy management systems.

There are a number of resources that can help organizations build and implement behavior change programs. Some of the organizations that have published useful case studies on this topic include the American Council for an Energy Efficient Economy (ACEEE), the Consortium for Energy Efficiency (CEE) and The Carbon Trust, among others.

Published by The Carbon Trust and modified based on my own experiences, the “Five Top Tips for Building an Effective Behavior Change Campaign” that can help organization get started on developing a behavior change program are:

1. Understand where energy is being consumed: Evaluate energy consumption across your organization and identify where behavior is a factor. Where the highest potential exists for energy savings may surprise you.
2. Prioritize the behaviors you want to change: Determine where you can realistically have the greatest impact. Potential energy savings should be balanced against the probability of achieving change.
3. Define the outcomes that you want to achieve: Decide specifically what goals or targets you are trying to achieve, so you can plan for how to monitor performance and feedback on the results.
4. Research what motivates or hampers good energy behavior in your organization: Use your understanding of your own organizational culture to help build your program. Find out what is important to your employees and how they think, behave and interact with the facilities, technology and others around them.
5. Secure top management support: Top management commitment and support is critical. They hold the resources. They can facilitate or block what it is you are trying to do. And, there is no substitute for leadership by example!

There appears to be enormous potential for energy savings from behavioral change. ACEEE recently estimated that the U.S. could cut energy consumption by 25% without hurting its economy. We know that technological advances will always provide important new solutions to reduce consumption within our highly energy-dependent society. But human behavior also matters in managing energy and achieving continual improvement in energy performance.

By: Holly Grell-Lawe, Project Manager (retired) Georgia Manufacturing Extension Partnership

As temperatures increase in the summer months, so do the risks that are associated with a lack of proper cooling solutions at your manufacturing plant. Keeping the factory floor cool during the hottest part of the year is vital to providing your employees with a safe and comfortable work environment, and can also prevent equipment and machinery failure. However, reducing heat to the necessary level within a manufacturing workspace can prove to be a challenge, especially when you are working towards becoming more energy efficient or do not have the budget for updating or purchasing new cooling systems. For optimum efficiency in cooling the factory floor and the rest of your building without incurring high energy costs, consider implementing some of following best practices at your plant:

1. Install High Volume Low Speed (HVLS) Fans. Proper air flow is key to reducing stratification. While standard fans may be able to provide some relief to employees, larger HVLS fans will be more effective when it comes to breaking up blocks of hot air and cooling the factory floor. Many HVLS fans are also programmable and can work together with other cooling equipment to lower temperatures. To ensure optimal results at your facility, you’ll need to consider a variety of factors, including blade size, the speed at which it rotates, and even the tilt of the blade. If you’re not sure which direction to go in, you can contact your local GaMEP region manager to help you find a reputable brand that can offer a variety of options and a free estimate.

2. Change the Color of Your Roof. Generally, darker colors absorb heat, while lighter colors reflect the sun’s rays. If your current roof is a darker color and traps in a lot of heat, consider replacing it with a light colored roof that will deflect more heat and keep the interior cooler, ultimately helping your plant become more energy efficient in the long run. If replacing your roof with new light colored materials is too daunting of a task or not within your budget, you may try applying a reflective roof coating to your existing roof. This type of coating is different from regular paint, but is applied in a similar fashion.

3. Insulate Your Building, Piping, and Equipment. Proper thermal insulation of your building, piping, and mechanical equipment is critical to managing the heat within your plant and can lead to lower cooling bills during the summer months. Without adequate insulation, the extra heat making its way out into your facility will make the air conditioning system work that much harder to cool things down. Simple devices such as thermal imaging cameras that connect to your phone can help detect energy loss caused by missing or damaged insulation, inefficient HVAC systems, electrical faults, and more.

4. Practice Preventative Maintenance. Performing regular HVAC maintenance will help your HVAC system run close to peak efficiency, resulting in reduced energy costs and preventing costly breakdowns. While HVAC maintenance may seem like an obvious necessity, small steps in the process can be easily overlooked, or you may assume that a certain noise is normal, or that a particular room may run warmer than others. Even something as simple as changing out the air filters can make a big impact. Ensure your facility is taking preventative steps when it comes to maintaining your HVAC by either recruiting an outside professional or looking to one of your qualified employees to routinely complete this work.

5. Shift Your Operational Hours. If your plant does not operate 24 hours a day and has some flexibility within its scheduling, you may consider shifting some of the operational hours to avoid using equipment during the hottest part of the day. By transitioning some shifts to overnight or earlier in the morning, your facility will experience less infiltration of heat and your employees will benefit from a cooler work environment.

6. Invest in Zip Doors. As your employees continuously move throughout the facility every day, the amount of times they open doors and let cold air out or allow warm air in can affect the air flow and contribute to increased temperatures. While you cannot control how every employee opens and closes a door, you can consider replacing your current doors with zip doors. After being opened, zip doors will automatically close – quickly and securely. Some versions may even offer verbal warnings that are triggered if a door is left open for too long. Zip doors also tend to be constructed out of softer materials, allowing them to better absorb any distress that comes their way and resist damage more easily.

If you are a small to medium sized industrial facility that is interested in implementing new or additional cooling solutions, but struggle to determine the best course of action then you may qualify for a no-cost assessment provided by the GaMEP. An IAC assessment will help you to identify opportunities to improve productivity, reduce waste, and save energy. To see if your company is eligible, apply at https://iacgeorgia.org/.

In addition, if you would like to discuss other energy cost savings opportunities or look at ways to improve your preventative maintenance capabilities, contact your local region manager at the GaMEP.

By Megan Johnson, with the Georgia Manufacturing Extension Partnership

Why You Should Consider an Energy Management System

Did you know that the GaMEP Energy and Sustainability Group contributed significantly to the content of the original ISO 50001 standard? Or that ISO 50001 may be able to help your company save a lot of money?

Randy Green, GaMEP project manager, has helped many companies throughout the United States (and the world!) implement energy management systems, such as ISO 50001. Read his responses to our most frequently asked questions about energy management below and then contact your region manager to find out if our energy management services could help your company.

What exactly is ISO 50001?

It is the International Standard for Energy Management, a set of guidelines and procedures designed to take a systematic approach to reducing energy waste throughout a facility.

Why is it important to be certified?

You can model some of the recommended behaviors and use the tools of ISO 50001 without becoming certified, which is a great first step. However, in my experience, companies that commit to the whole system and take a structured approach to energy management, see the most value and experience the continued and sustained benefits of the program. Many of the companies I have worked with have even chosen to take the next step and become Superior Energy Performance (SEP) certified as well, which is a designation given by the U.S. Department of Energy to companies that have demonstrated their energy performance through their metrics.

Does this only work for large companies?

No- we have helped companies of all sizes and in many different industries save money using these systems.

Is it expensive?

The initial cost to get the certification is usually around $10-15K. You will also need to allocate some staff time (and salary dollars) to implement and maintain the program. However, the bulk of the efficiency improvements usually come from behavioral change, not from investing in new or upgraded equipment. Both ISO 50001 and SEP are really about culture change and making energy management a part of everyone’s job, which means you don’t have to spend a lot of money to get real results.

Do you have any case studies?

The U.S. Department of Energy has released a series of case studies (many of which are about companies that GaMEP project managers have assisted.) I will link a few below, however, we don’t have a lot of case studies in the state of Georgia- something we would like to change- so contact us to be one of the first companies in the state to benefit from these systems and certifications and from having this unique expertise right in your back yard!

Case Studies:

• Nissan Improves Energy Performance 24% over Six Years
• HARBEC—a Specialty Plastics Manufacturer—Improves Energy Performance 16.5%
• 3M Saves $3.6 Million through Implementing SEP Enterprise-wide

If you are a small or mid-sized manufacturer in Georgia or North Florida, you may qualify for a no-cost assessment that will identify opportunities to help you save energy, reduce waste, and improve productivity. The assessments are done by staff and students from Georgia Tech, Florida State University, and Florida Agricultural and Mechanical University (FAMU). On average, each assessment identifies opportunities to save more than 10% in annual energy expenditures.

Still wondering what type of a commitment it requires from you, what to expect, and what benefits you will receive if you participate? Read on to understand the process from start to finish. Then contact us to check your eligibility and schedule your assessment!

Step 1- Understand energy trends and make an energy balance.

After the company fills out a short application and provides some basic information, the IAC team takes the energy consumption information provided on past bills and equates that amount with major energy uses within the facility. Energy uses are the application of energy in the facility, typically through equipment and machines. This process, called an energy balance, helps the team focus their efforts to create impactful recommendations, estimate cost savings, and develop accurate payback periods for new investments. It also allows the team to gain a general understanding of the facility before the site visit.

Step 2- Discussion with plant manager or other designated company representative.

The site visit starts off with a brief meeting discussing the audit procedure and what to expect. We then ask various questions about the facility based on the Georgia – North Florida IAC Application, such as:

• How many people are employed here?
• Is this a seasonal operation or do you operate year round?
• What products do you make and how many production lines are there?
• What is the significant energy consuming equipment in the facility?
• When was your facility built?
• Do you have specific energy goals or initiatives already planned or being considered?

Step 3- Walk through of the entire facility.

In this step our team inspects the facility to get a basic understanding of the manufacturing process and how the operation works. The team records information about:

• The manufacturing process and how equipment is utilized throughout the plant
• Nameplate ratings for major equipment
• Compressed air, lighting, HVAC, and other major equipment that consumes electrical energy
• Boilers, ovens, heaters, and other major fuel-consuming equipment
• Structural design in regard to energy use

Step 4- Speak with facilities/maintenance personnel.

Next we interview a representative from facilities and/or maintenance to help us gather more in-depth information about the machines and facility that could not be easily obtained during the walkthrough. We also ask about current maintenance schedules to understand what opportunities for improvement might be available through adjustments to your maintenance routine.

Step 5 – Meet as a team to discuss ideas and create an action plan for the rest of the day.

We regroup, discuss ideas, and research information that might be helpful as we complete the assessment. Then we create a plan for the rest of the assessment that will include more data collection and information gathering to help us develop cost-saving recommendations.

Step 6 – Data gathering.

The team uses data monitoring and measurement equipment to record information about potential opportunities. This could include any of the following:

• Logging electrical consumption of major equipment over the course of a week
• Logging temperature and humidity levels to determine effectiveness of HVAC equipment
• Measuring temperatures of uninsulated equipment and pipes
• Sampling and analyzing exhaust gases to determine combustion efficiency
• Recording lighting levels throughout the facility

Step 7- Closing meeting and follow up.

Finally, the team discusses observations with the plant manager and other staff members that were involved in the process and makes some initial recommendations based on what was observed in the plant. Then over the course of the next two months, the team will analyze the data to provide a comprehensive report to the company. The report includes an analysis of energy trends over the past year, a complete energy balance of the facility, and five to ten recommendations for reducing waste through energy and water consumption, as well as productivity improvements. Each recommendation includes a simple payback analysis tailored to the client’s requirements. Six to nine months after the report is delivered, the IAC team will follow up to find out if the recommendations were implemented and if the results were as expected.

The initial assessment takes about eight hours and within two months you receive an in-depth report with all of your energy information in one place, recommendations from our team of energy experts, and even estimated cost and payback period for potential investments. This program is provided by the U.S. Department of Energy to help small to mid-sized manufacturers achieve the same level of energy efficiency as large manufacturers; helping you save money, remain competitive, and grow your business.

Take advantage of this free resource! Find out more at www.iacgeorgia.org or contact Sinan Sinharoy, IAC Assistant Director and GaMEP Project Manager, at ude.hcetag.etavonninull@yorahnis.naniS or 412-559-2777.