Facility Type

1.2 million square foot Manufacturing Facility and Office Space

Installed Equipment

Custom air compressors

DP&L Rebate

$227,794

Expected Annual Electricity Savings

$227,453

Payback

Cut from 24 months to 12 months with DP&L’s rebates

With nearly 1,100 employees working 24/7, it’s critical for Behr Dayton Thermal Products in Dayton to operate air compressors needed for production equipment in the most cost-effective and reliable manner.

“We cannot afford to operate without uninterrupted compressed air,” said Boris Nodel, Facilities Manager for Behr Dayton Thermal Products.

Nodel explained that in a market as competitive as automobile manufacturing, every penny counts, especially if you are competing against plants in countries where costs are lower.

Making the Behr America facility in Dayton more cost effective by cutting energy costs “helped to set us up as one of the more competitive plants in the industry,” he said.

The facility in north Dayton is one of 22 Behr production locations and 10 joint ventures worldwide. The company is a leader in innovations for climate control and engine cooling for automotive and truck manufacturers such as GM, Ford, Mercedes, BMW, Chrysler, PACCAR and Freightliner.

Before 2011, the 1.2 million square foot facility at 1600 Webster Street used several outdated water-cooled air compressors that also required several cooling towers – adding expenses for water and sanitary sewer.

To reduce costs and save energy, the facility switched from an over-sized, outdated 900-hp constant speed air compressor cooled by water to a 270-hp variable speed air compressor which is air-cooled, gaining energy savings of 2,156,900 kWh with a peak demand reduction of 223 kW. This first phase was completed in March 2011.

For the second phase, completed in July 2011, the facility added two 150-hp air-cooled constant speed air compressors, which allowed the company to better match the plant’s  compressed air demand and retire two high pressure compressors.

Each of the three new air compressors has efficiency ratings above 95 percent.

The total energy consumption and peak demand savings for both phases was 3,249,332 kWh per year and 361.3 kW.

“Also, by eliminating the cooling towers, we saved quite a bit of water,” Nodel said.

The energy survey determined that getting rid of the cooling towers also saved Behr Dayton Thermal Products 323,302 kWh per year because of energy costs for fans, pumps and heat tape used in the towers.

The project to improve the energy efficiency of its air compressors also qualified Behr Dayton Thermal Products for Dayton Power & Light’s energy rebates after completing a survey verifying the energy savings.

For Phase 1, Behr Dayton Thermal Products received a Custom Rebate of $126,570 from DP&L. For Phase 2, the facility’s Custom Rebate from DP&L was $101,224.

“We are very pleased with the results of our compressed air project,” Nodel said.

Businesses like Behr Dayton Thermal Products and others around the Miami Valley are saving thousands of dollars by improving and upgrading their facilities with energy efficient HVAC systems, motors, drives and compressed air systems.

Upgrading or replacing systems like air compressors or lighting also qualifies a company for rebates from DP&L. Controlling energy costs positively affects a company’s bottom line and is an important component of any company’s green initiative.

After the success of the air compressor projects, Behr Dayton Thermal Products made plans to replace its old fluorescent and HID lighting with more efficient lighting.