energy Archives - Unitherm Insulation Systems

January 21, 2015 by UniAdmin

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

May 21, 2013 by Kendal White

The Future of Energy Efficient Vehicles + (Infographic)

Flying cars were expected to be the future by 2000; despite erroneous expectations, cars have become radically advanced within recent years. Cutting-edge technology has prompted the birth of the car of the future due to anxieties of energy efficiency and rising pollution.

By 2025, all new U.S. vehicles must be equipped with a 55mpg+ fuel range. To contend with new fuel regulations, each year a car must be 5% more fuel-efficient. The price at the pump is expected to increase 25% by 2025; presently, the average vehicle gulps an annual average of $1700. Future hybrid & electric vehicles may cost $2400 more, but consumers will save $8200 in additional expenses.

Plug-in vehicles (PEV) or electric vehicles (EV) are gaining in popularity, but critics cite inflated prices, shortage of fueling stations, and limp technology advancements as probable disappointments. Despite the EV knockers, the Tesla Model S recently earned Car of the year for 2012 by Automobile Magazine and received Motor Trend’s Car of the Year honors in 2013. Cadillac, BMW, Audi, and Honda are soon to follow in the EV trend in 2014.

Alternative fuels are the clean fuels of the future: liquid petroleum gas (LPG), ethanol, biodiesel, and natural gas. LPG and natural gas are undoubtedly promising; these domestic fossil fuels yield less toxic pollutants and greenhouse gases. Biodiesel, unlike its petroleum counterpart, originates from vegetable oils and animal fats. Corn and other domestic crops create ethanol. The government promotes these unorthodox fuels with alluring tax incentives to qualifying consumers.

House Bill 2453 may leave an unpleasant taste in some consumer’s mouths after it is passed. This tax, to be blunt, fines individuals to drive an electric vehicle. This gas tax would be aimed at 2015 or later vehicles, with 55 miles/gallon or more. A little background information: 60% of state projects are funded by taxes on gasoline. Thus, states are collecting less tax money because of existing and future electric and hybrid vehicles. Point blank, the fee would be 1.56 cents per mile.

These destined energy efficient vehicles could conceivably constitute 65% of the market in 2025. Consumer demand, credits, and government incentives will determine the car dealership of the future.

April 23, 2013 by Kendal White

Renewable Energy And The Crusade Towards Innovation

Renewable energy is continually replenished and non-polluting: geothermal, sun, water, and wind. The popularity of renewable energy is growing due to high oil prices, change, government legislation, and mounting government support paired with incentives. Greenhouse gases are detrimental to the Earth’s atmosphere; these gases allow sunlight to enter the atmosphere, thus trapping heat in the atmosphere. These rising temperatures may trigger climate change. Greenhouse gases in North America are primarily from energy consumption due to economic growth

Solar power technologies utilize the sun’s energy to provide electricity. Solar power supplies less than 1% of U.S energy requirements; nevertheless, solar technologies are quickly advancing. Solar technologies used for harnessing solar energy include photovoltaic cells, passive solar designs, and flat-plate collectors. The applications used to adapt solar power into electricity are costly, yet, the substantial potential of solar energy remains.

Hydropower is the most conventional renewable energy source, and uses flowing water to produce electricity. Major dam sites in the United States include the Tennessee Valley, the Colorado River, and the Northwest. Hydropower is suitable for supplying large electricity requirements and is the least expensive renewable energy source.

Wind energy applies wind turbines to generate electricity; this sector of renewable energy is the fastest growing. Ideal placement for turbines is in an area of strong winds: Alaska, the Appalachians, and the western United States.

Geothermal energy utilizes natural sources of heat trapped beneath the Earth. Underground hot water or steam is the conventional form of generating power. Geothermal technologies embrace geothermal heat pumps, direct-use systems, and reservoirs.

Innovative technologies continuously attempt to improve the employment of renewable energy.

Livestock methane gas emission is a severe threat to the global climate. In British Columbia, the Cowpower Program encourages residents to pay a slight percentage on their utility bill. This premium will help pay for an anaerobic digester- bacteria is converted into organic material, creating energy.

Groundbreaking transportation could ease the reliance on fossil fuels for energy. The invention of a speed vacuum train could be reality in the near future. A speed-vac train is based upon the idea of removing the air from a sealed tub, and pressing a train through. Conventional trains use a great deal of energy; the vacuum theory would be matched with magnetic levitation devices, allowing trains to reach 4,000 mph.

The latest in solar technology has spawned the idea of a device to trap light, which progresses the proficiency of organic solar shells by 175%. This “black hole for light” could possibly allow for an economical, marketable solar shell.

May 1, 2012 by Kendal White

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.

April 24, 2012 by Kendal White

International Standards for Energy Management: How ISO 50001 Can Help Companies of All Kinds

“Individual organizations cannot control energy prices, government policies, or the global economy. But they can improve the way they manage energy.” –ISO Secretary-General Rob Steele

Energy is one of the largest controllable expenses of your plant, or of any building for that matter. And luckily, as more and more building owners realize remarkable ROI in energy-saving strategies, the amount of related information continues to grow.

In fact, a quick Google search for energy management returns about 54,800,000 results, which gives us about 78 pages to wade through. Of course, no one has time for that, so we usually just collect tidbits of advice we hear about going green and put them to use as best we can.

For example, at home I know to keep the thermostat under 68° in the winter and over 72° in the summer for better energy savings. I know to run the dishwasher only when it’s full to maximize water use. I know to open the shades during the day to let in natural light. I’m sure you’ve heard similar rules of thumb.

So we’ve got the basics down, but managing energy in an entire plant requires a bit more forethought than simply turning off the lights when we leave the house.

download avaiable at iso.org

Fortunately, the International Organization for Standardization (ISO) launched an energy management standard last summer. According to ISO, the energy standard—ISO 50001—will provide industrial plants, commercial, businesses, government facilities, and entire organizations with “access to a single, harmonized standard for implementation across the organization with a logical and consistent methodology for identifying and implementing improvements.”

Twenty-six US facilities, including 3M, Cook Composites, Dow Chemical, Nissan, and Volvo, participated in ISO 50001 pilot programs. In addition, the Department of Energy endorses ISO 50001 as a “proven approach for US industrial commercial facilities to plan, manage, measure, and continually improve energy performance.”

Companies implement these energy standards to reduce their energy consumption and environmental footprint, but they can become ISO 50001 certified as well. On March 8^th of this year, Volvo’s Dublin plant was the first US facility to achieve certification. This third-party verification can afford companies a competitive edge and greater confidence in their supply chain.

For those that utilize it, the energy standard will be hugely helpful as it takes the guesswork out of energy management. Instead of the trial and error strategy I use at home, haphazardly turning the thermostat up or down, ISO 50001 provides an explicit framework applicable in any company—public or private, large or small. Companies worldwide can now adopt best practices in energy management.

Have you begun working towards your ISO 50001 certification? What other energy management tools—software, audits, etc.—do you use at your facility? If you’re kicking off a new energy management program or you’re working to keep your energy output in check, get a customized energy report today.

March 29, 2012 by Kendal White

Keep the World’s Pipelines in Good Working Order

We are a world on the move. Transportation is key to our way of life, and I’m not just talking about planes, trains, and automobiles here. Sure we move ourselves all the time, but think about all of the commodities we keep in transit. We send packages, parts, products around the world everyday. From space we probably look like busy worker bees in whirlwinds of constant motion.

The invention of modern vehicles transformed the way we operate in daily life—we revere innovators like Henry Ford and the Wright Brothers for their contributions, but rarely do we recognize how important pipelines are in our society

Pipelines allow us to transport any chemically stable substance. We’ve built pipelines for sewage, slurry water, and even beer. But arguably the most valuable are those transporting fuels. I would venture to say that no one in the oil and gas industry underestimates the value of the pipeline.

Since the 19^th century, we have amassed 2.3 million miles of pipelines in the US alone. Compared to other shipping methods, pipelines have lower cost per unit and higher capacity, and they can handle the dirty stuff we don’t really want spilling out into the environment. For this reason, it is absolutely essential that we take good care of our precious pipelines.

This is how SolarShell has entered the oil and gas industry. The fiberglass laminate is great for repairing steel, concrete, insulation glass, and wood applications, but its capabilities don’t end there. With an infrastructure as massive as the pipeline, we must always be planning ahead. SolarShell is a wonderful way to prevent corrosion and protect against future damage.

SolarShell is resistant to chemicals and thus perfect for protecting pipes. One oil and gas company coated the outside of a large pipe with SolarShell before installing and burying it underground. Pipes protected with SolarShell—whether buried, dragged, or exposed to the elements—show no signs damage.

Laminate curing in the sun

It would be nice if pipes and other important equipment could outlast the relentless forces of Mother Nature, but most of the applications we rely on require extra reinforcement. Luckily, laminates like SolarShell exist for that very reason. What is essential in your industry that could benefit from the added support of SolarShell?

March 13, 2012 by Kendal White

See it to Believe it: The Benefits of Thermal Imaging

When thinking about energy output in a manufacturing plant, it’s natural to go to the lights and the HVAC. This makes sense since these are typically the top energy expenditures, but it’s a plant’s machines that devour more energy than all other utilities combined. That’s right, machines consume about 60% of total energy costs. How do we know this? Well, government agencies and other entities provide plenty of studies and statistics for us to read over, but why not see the energy output for yourself?

Thermography is more than fancy spy gear for secret agents to expose hidden enemies—it has a wide range of commercial and industrial applications for those of us in the real world as well. For manufacturers, thermal imaging allows you to visually track the amount and consistency of heat emitted by your equipment. With a thermal camera, you can compare the output of the different heat sources (even those not-so-easy-to-access heat sources) in your facility from a comfortable distance. This way you can find defects in shafts and pipes and locate deteriorating components before they fail.

Equipped with a thermal picture (a thermogram, in case you want to sound technical), you can easily spot the energy hogs highlighted in yellow, orange, and red—so you know exactly what areas to target as you take steps to reduce your energy costs.

Thermal Imaging

Immediately you’ll see your machines light up hot—as they should, that’s how they work. But most likely they don’t need to be operating that hot or emitting as much heat as they do.

The good news? Machines represent your greatest opportunity to conserve energy. Instead of idling, consider powering down equipment during non-peak hours, make sure motors are working as efficiently as possible, and insulate, insulate, insulate. The ROI is remarkable—insulation saves an average of $164 per machine per month. See what thermal imaging reveals so you can start saving.

February 21, 2012 by Kendal White

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.

February 14, 2012 by Kendal White

More Energy Rebates for More States

We recently wrote about energy rebates and incentive programs offered in Michigan to manufacturers who take action to save energy. Well, we have more good news. Duke Energy’s Smart $aver Incentive Program now offers businesses in Kentucky, Ohio, and North and South Carolina energy rebates for installing equipment such as high-efficiency lighting and HVAC pumps.

Energy rebates in Kentucky, Ohio, North and South Carolina
Duke Energy’s Super $aver program is designed to help businesses offset up-front costs, shorten payback periods, and improve their bottom line by reducing energy output. Companies can qualify for different Super $aver incentives based on their type of equipment—Duke Energy offers incentives for lighting, thermal storage, premium motors, process equipment, and many more.

In addition to providing a list of prescriptive incentives, Duke Energy also offers a Smart $aver Custom Incentive Program to its commercial and industrial energy customers.

Ask your account manager about how to enroll in a Smart $aver Program. And remember, UniTherm offers insulation jackets to keep your equipment insulated and efficient. Be sure to explore all avenues of energy efficiency.

Live in one of the other 46 states?
EnergySavvy.com is a great resource that lets you search for energy rebates and incentive programs in your area.

Check back soon for more energy incentive updates.

November 22, 2011 by Kendal White

Energy Rebates Exponentially Increase ROI

To encourage customers to conserve electricity, energy providers across the country are offering their customers some very generous special offers, such as rebates on qualified insulation products. This is one green-friendly program that can save a company significant green-backs for years to come.

UniTherm Insulation Systems is here to help you “green your machines” by providing insulation products for the plastics industry. Our insulation blankets are high return, low investment insulation solutions that can lower your energy bill, protect your employees and lower the ambient air temperature in your facility. With off-the-shelf blankets and the ability to custom design to meet any company’s insulation needs, (altered with slits, cutouts, and/or other augmentations) we make it easy for you to make significant strides toward greening your organization and lowering your monthly electric bill.

SMR saved $17,297

Many have already cashed in on their energy provider’s current discounts and rebates, like Samvarhana Motherson Reflectec, a member of Samvardhana Motherson Group, who recently saved 55% on the purchase of insulation blankets for their largest injection molding plant that houses 45 machines ranging from 250 to 1,000 tons.  Their total savings: $21,250.

96% of Purchase Reimbursed

Another Michigan-based company was faced with the too common concern of spiraling energy costs and needed a way to reduce its environmental footprint for the five 2,000 ton injection molding machines the company uses, but didn’t want to break the bank in the process. After learning of the special rebate from their energy provider the injection molding company decided to purchase qualify insulation products, a decision that will continue to save them money for years to come. Their rebate totaled $15,075, saving 96% on the total purchase.

Mold Masters Company Received $21,725 in Rebates

Heat loss costs organizations hundreds of thousands of dollars annually, but can be prevented with the proper insulation system. With the increased concern for more energy conservation, many companies, like Mold Masters Company in Lapeer, Michigan, will want to take advantage of one of these generous offers provided by energy utility companies all over the country. As a leading manufacturer of thermoplastic parts for the auto industry, Mold Masters Company needed to insulate their entire facility of 40 machines. Ranging in size from 85 tons to 2,450 tons, their rebate totaled $21,725. Mold Masters Company only paid $11,794 out-of-pocket for their $33,519 worth of insulation blankets.

So do these insulation blankets actually work? The answer is yes. Just ask Prism Plastics, who needed their 220 ton Sumitomo machine insulated. According to St. Criox Electric, their energy savings totaled 39.24%. Samvardhana Motherson Reflectec (SMR) is now saving 13.6% on their energy bills for their entire facility – and they expect to save even more in the summer months.

UniTherm insulation blankets have a typical pay-back in as little as 12 months. Add a big-bucks savings rebate from your energy provider and that time frame is significantly decreased to 3 – 4 months or less. You’ll continue to save year over year for the life of the blankets – making the ROI higher and faster than any other energy savings programs you can implement in your facility.

Typical incentive programs differ from state to state and company to company, but on average the offer is $1 per ton on blankets for injection molding, extrusion, blown film, and blow molding and $10 to $30 per linear foot on insulation for pellet dryer ducts (making your out of pocket costs about 50% less on machines and 90 – 120% less on dryer hose insulation).

To find out if your provider is offering a rebate program just give them a call. Be sure to check the details for specific machines and purchasable products.

Companies who have already cashed in on this incentive are doing their part to reduce energy consumption and are moving the savings straight to their bottom line.

Our sales representatives are here to help you start saving.