Milliken

Business: Textile Manufacturing

Bay upgrades control hardware and improves compressed air systems at Milliken Container allowing for centralized Engineering Support.

Project Scope

Milliken Container and Bay Controls implemented a state-of-the-art compressor control system for Milliken Container plants (9 facilities and 38 air compressors). Air compressors at each site were upgraded with the Bay Controls Air Compressor Controller and integrated using distributed capacity control technology. In addition to the controls standardization, the project included internet-based monitoring of all air compressors via Bay's BayWatch service allowing corporate air specialists to assist each plant.

Project Summary

By utilizing the Bay Controls air compressor control system, each plant was able to optimize their compressed air requirements relative to energy use. The internet-based BayWatch monitoring system provides Milliken Container with continuous real-time and historic air compressor performance information. We able to achieve a 1-2 psi pressure control window at all plants which allowed the plants to run fewer units thus saving energy. Additional benefits included in this project were Bay Controls' auto start/stop, performance log, and scheduling software. This project included all engineering, labor, and training for a turnkey installation.

Energy Savings

Projected annual energy savings of 11%.

Project Cost

Total project cost was $725,000.

Payback

The payback period for this project was 20 months.

Other Benefits

Productivity, reliability, and maintenance benefits were realized with this project as well as energy savings.

Monitoring and Verifying Energy Savings

The BayWatch service was employed to monitor and verify energy savings.