4 Common Misconceptions About Industrial Insulation
We come across many people who have the wrong idea about industrial insulation and think what we offer is not right for them. We ask them a few questions, and usually they are left wondering why they haven’t insulated their equipment sooner. We throw them a UniVest and they rush out the door to install it (cause it’s really that simple).
So we don’t have to go through the same spiel every time, we’ve compiled the most common misconceptions people have when it comes to industrial insulation.
1. Insulation is for my home, not my machines
This is the most common one we come across and it’s pretty obvious why. The first thing people think about when you say insulation is their home and what’s inside their walls. That’s a perfect analogy because UniVests work the same way. Properly insulating your home saves you hundreds of dollars a year on home heating and cooling costs. It protects outside temperatures from affecting the temperatures you want inside. The easier it is for your home to maintain its temperature, the less you spend at the end of the month. UniVests are no different, except we deal with higher inside temperatures. Take a second and think, if you save hundreds by properly insulating your home, imagine how much could be saved when insulating your machine. We’ll give you a hint…its much greater!
2. No Budget for Insulation
We all have budgets. Yeah, and we know they can be small and hard to deal with. Trust us, Windows 98 is getting really old at the office. Making new purchases on things that you are already operating without can seem like a luxury purchase. Little known fact is that with proper insulation, a company can see ROI (Return on Investment) in under 12 months. In the right conditions, a single set of UniVests or ISOCOVERS can last 5+ years after installed. That’s 5+ years of return. In 12 months or less, most companies make back the purchase price of a UniVest from energy savings alone.
3. My machines are working fine now without insulation
We’re sure they do, but wouldn’t you like for them to work better? Insulation minimizes the downtime of the machines they are on and relieves stresses from a hard working machine. This even increases the lifespan of the equipment. Wouldn’t we all like to work a little easier? Your machines would too.
4. Who Needs Protection Anyway
The biggest thing that people don’t realize is that insulation also improves workplace safety. As seen in a few of our videos on Youtube, a heated barrel with a UniVest on it can be touched and worked around without any special protective gear. More Safety = Less downtime and less liability. Insulation can also decrease surrounding ambient air temperature. Decreasing work fatigue due to high temperature and more comfortable work areas.
Here’s typically the point where some people are kicking themselves for not already having insulation installed. If you didn’t make it this far, we completely understand. Our insulation systems are much more than the sum of their parts and offer a lot more usability than most people realize. If you’ve finally come to the conclusion that insulation could benefit you, take a look around our online shopping cart at www.shop.unitherm.com. For some help finding the product, measuring, or just want some more insulation entertainment like this blog, visit our youtube page: www.Youtube.com/UniThermInsulations
Budgeting For Energy Efficiency Projects
Companies always look to make the best decisions when selecting capital projects to work into the budget; simple metrics like Return on Investment and Internal Rate of Return tend to dictate how the budget for these projects is written each year. In an effort to increase the bottom line, investments are often times funneled toward projects and purchases that directly affect sales rather than decreasing operating costs, but sales growth is never guaranteed.
In other cases, capital projects are indefinitely suspended, forcing companies to make due with what they have until either more funding becomes available or sales increase. [Read more…]
Smart Grids: Bringing Utility Systems into the 21st Century.
What is a smart grid?
Just as smart phones have evolved into multi-purpose devices that support a wide range of applications, smart grids have become a way to computerize the electric utility grid and better manage the increasing energy needs of 21st century consumers.
The “grid” encompasses all the networks that carry electricity from the plant where it is generated to the homes and office buildings where we consume it. Smartgrid.gov refers to our current grid as an “aging infrastructure” set up to handle only simple energy demands.
For the past 100 years, utility workers have had to go out to gather much of the data needed to provide electricity — reading meters, looking for broken equipment, measuring voltage, and so on. And most of the devices utilities use to deliver and manage electricity rely on manual or analog systems. Now, the electricity industry is taking great strides to modernize the process.
A smart grid system digitizes data collection and also acts on information about consumer behavior — similar to the way Google learns your online searching habits and Netflix knows your movie preferences. Each device on the network has hi-tech sensors to gather data and automation technology that allows the utility company to adjust and control each individual device or millions of devices from a central location.
In addition, a smart grid system can
- Detect faults and isolate outages
- Restore electricity quickly and strategically after power disturbances
- Reduce management costs for utilities, lowering power costs for consumers
- Reduce peak demand, which will also help lower electricity rates
- Enable active participation by consumers in demand response
- Integrate large-scale renewable energy systems
- Integrate customer-owner power generation systems
- Operate resiliently against physical and cyber attack
Who supports the smart grid?
In 2007, Congress passes the Energy Independence and Security Act, which supports the DOE in leading and coordinating a national grid system. Such a system would involve upgrading the current system or replacing it altogether. Smartgrid.gov advocates that a modern grid be constructed “from the bottom up to handle the groundswell of digital and computerized equipment and technology dependent on it.”
In 2009, the Obama administration allocated $3.4 billion in grants as part of a stimulus package to help utilities develop and implement technologies such as smart meters, digital transformers, and automated power monitoring and management systems.
We have seen smart grids deployed on a smaller scale in cities like Austin (2003) and Boulder (2008), and several areas in Europe and Canada are currently working towards large-scale smart grid systems.
Smart grids are designed to give consumers more control over their energy use. Imagine monitoring and managing electricity just as you do your bank account. Smart grids will provide a clear and timely picture of how much electricity you use and when it costs the most to run.
To learn more, download the DOE’s Smart Grid System Report, and check out unitherm.com for more ways to take control over your energy expenses.
Manufacturing Matters: 5/4 Weekly Wrap Up
Another great week ripe with industry news. Here are the highlights:
Plastics News reports that the shortage of nylon 12 has led the auto industry to seek alternatives resins to use in fuel lines, connectors, tubes, and other key components. Molders and resin makers have offered a variety of possible alternatives, and automakers have established a system to begin testing.
The Huffington Post addresses the current the job market as US Congressional Candidate Stacey Lawson proposes a plan for creating jobs and rebuilding our middle class. Lawson stresses that we can by reclaim the American dream by “restoring the high-wage jobs that are the foundation of a sustainable economic recovery,” and she lays out 7 priorities to help us get there.
Clean Technica overviews the Department of Energy’s voluntary energy savings specifications designed to help building owners, operators, and manufacturers develop minimum performance requirements. The DOE recently released new specifications for lighting troffers and parking lot lighting, which could reduce energy use by 40%.
image from cleantechnica.com
Industry Intelligence announces a new compostable bioplastic film that extends the shelf life of fruits and vegetables by up to five days. The new film, developed by Sira-Flex Resolve, creates an ideal atmosphere to better preserve stored food.
image from flickr, courtesy of I-5 Design & Manufacture
And in a free webinar, Design World discusses how Design for Manufacturability (DDM) eliminates many restraints associated with conventional manufacturing. The webinar examines how DDM can create plastic parts, layer-by-layer without machining, molding, or casting.
If you like the Weekly Wrap Up, follow our blog to receive more updates and industry news every Friday.
How to Join the Better Buildings, Better Plants Challenge
Going green. Saving energy. Encouraging efficiency. Reducing carbon footprints. Promoting eco-friendly practices. Being environmentally conscious. Conserving resources. It goes by many names, but the social movement is undeniable.
I remember seeing for the first time the trendy “Save the Planet” tees cropping up in clothing lines of popular retail stores. Years later, it turns out that going green more than a fashion trend. It is a compilation of personal and political choices that continues to build momentum worldwide.
We can see big impacts, too, when we look at the sum of our efforts. That’s why government and corporate entities promote going green, leading by example and initiating challenges to get others involved.
Better Buildings, Better Plants Challenge
Last year, President Obama and former President Clinton issued the Better Buildings Challenge and extended the challenge to industrial plants for an even greater impact. Because buildings consume about 20% of all the energy used in the US, the initiative’s long-term goals include
- Updating American buildings to make them 20% more energy efficient
- Saving American businesses nearly $40 million in energy costs
With the help of energy efficiency products, services, technologies, and partnerships, several industrial partners have stepped up to the challenge—3M has 78 participating plants, Alcoa has 30, Nissan has 3, and GE has 125 million sq. ft. of plant space (to name a few).
But you don’t have to be a big name with copious plant space to make a difference. Think of it this way—as a little guy, your carbon footprint is already smaller so you don’t have to make such extravagant changes. Every little bit counts.
To join the Better Buildings, Better Plants Challenge
- Assess your building portfolio to determine energy efficiency opportunities and publicly pledge an organization-wide energy savings goal for the next 2-5 years.
- Announce and initiate a showcase project on 1 facility (retrofit, retro commissioning) and develop an organization-wide plan to achieve your energy savings goal.
- Share your experiences with energy efficiency solutions, your organization-wide energy savings, and the energy performance at individual facilities for recognition.
In return for your commitment, the Department of Energy agrees to support you via expert technical assistance, connect you to a network of allies, and provide you with national recognition. Win-win-win.
What are you doing to green your building? The Better Buildings Challenge is just one way you can contribute to the social movement. Incentives are abundant, and the payoffs reach far and wide. For starters, you can insulate your equipment to conserve energy and maximize efficiency, and when you start seeing the savings, you can move on to other areas like HVAC and lighting for a complete energy-efficient overhaul.
The Best Ways for Manufacturers to Save Energy: Surveying the Site
Who doesn’t want to save energy? Now more than ever, we are all looking for ways to cut back—we turn down the lights and turn off the thermostat, we run the dishwasher less and take shorter showers—hoping to save some money on the monthly energy bill.
But when you run a large manufacturing plant, the task of saving energy may be a bit more daunting. Before you can start conserving energy, you have to know where the most energy is being consumed and what the best opportunities are for reducing high-energy output.
Knowledge is power, so we’ve put together a simple site survey checklist to help managers get well acquainted with their plant’s energy output. According to the Energy in Plastics Good Practice Guide, you should carry out an initial survey immediately because “if energy is being wasted, it is costing money.” A 20% cut in energy costs can equal the same bottom line benefit as a 5% increase in sales.
It’s also a good idea to take an unannounced walk around the site at about mid-shift to see how things are running during normal working hours.
What to look for during an initial walk through
Keep a close eye on the machines. Machines consume about 60% of energy costs. Yikes. But think of it this way—here lies your greatest opportunity for energy savings.
As you survey the site, keep these questions in mind:
- Which areas have the largest energy load? Look for the largest machines; they will have the largest motors and consume the most energy.
- Which motors are running? Would smaller motors be more efficient? Could they be turned off during non-peak hours?
- Are machines well insulated? Is the insulation in good condition?
- Are hot and cold pipes insulated? Is the insulation in good condition?
- Which cooling water pumps and vacuum pumps are running?
- Does compressed air pressure need to be so high, or the vacuum so low? Can you hear steam and compressed air leaks?
- Are lights and machine heaters left on? What is running during lunch breaks and and after working hours?
With a better understanding of where unnecessary energy output occurs, you can now take productive steps to decrease it. Don’t wait—conduct your site survey today to start saving energy and increase that bottom line!
*Statistics from European Best Practice Guide.
5 Keys to Survival After the Recession
The United States economy is slowly recovering from the so-called Great Recession and many manufacturers are looking to the future. With a surge in international manufacturing, increased competition has company leaders desperately searching for ways to survive and grow in today’s volatile economy.
With manufacturer’s in mind, UniTherm is launching the “5 Keys to Survival After the Recession” series. The series focuses on ways that manufacturers can lower supply chain costs, raise profits and compete in an increasingly competitive market.
Over the next few weeks, we’ll feature ideas and strategies for ways to increase manufacturing products by focusing on innovation, reducing overhead costs and resource waste, improving consistency, and modernizing marketing efforts to increase yield.
Would you like to see your company featured in the “5 Keys to Survival After the Recession” series? Let us know what steps your organization is taking to be more competitive and we’ll feature you throughout our series.
Don’t miss the first installment of “5 Keys to Survival After the Recession,” subscribe to receive updates from the UniTherm Blog.