There are two objectives of the IAC program. The first is to provide a free service to manufacturers to identify monetary savings from reduced energy and waste costs and increased revenue from productivity enhancements. The second is to provide an educational opportunity to engineering students through on-site plant visits, data analysis, and technical report writing.
General information about the manufacturing facility is gathered prior to the on-site visit. This information includes utility bills, an overview of the manufacturing process, and areas of potential savings as identified by the facility manager. Once this information has been analyzed, a date is set for the on-site visit.
An IAC assessment team conducts the on-site visit. The team consists of engineering students and faculty who have been trained in performing the assessments and who have had industrial safety training for general plant operations. The one-day visit involves an orientation meeting with plant personnel, a plant tour to observe key processes, data collection, and a wrap-up meeting.
A detailed engineering report is provided to the facility manager within two months of the on-site visit date. The following items are included for each recommendation:
- Expected savings
- Detailed technical calculations
- Implementation costs
- Payback calculations
An important component of the IAC program is to gather implementation data from the facility manager regarding the recommendations suggested in the IAC report. This information is requested from 6-9 months following the issuance of the report. The plant is under no obligation to implement any of the recommendations presented in the report; however, it is hoped that recommendations made will show sufficient payback to warrant careful consideration by plant management.
A Few Examples of What We Analyze
Energy Savings Measures
- Lighting and HVAC system retrofits
- Heat recovery applications
- Compressed air leaks survey
- Motor upgrades
Productivity Enhancement Measures
- Bottleneck mitigation
- Labor optimization
- Raw materials cost reduction
Waste Minimization Measures
- Process changes
- Recycling programs
- Solvent alternatives
You may also download a printable version of our sample report (455 KB pdf).