Real-Time Energy Monitoring Case Study

Customer: Dylan Aerospace
Location: Auburn, Washington
Industry: Manufacturing
Current Annual Consumption: 325,000 kWh
Annual Energy Cost: $33,000

Problem

Rising energy costs from operations. Planned manufacturing/operation expansion, but existing power capacity is unknown.

Goal

Reduce increasing operating costs through energy efficiency upgrades, sustainable business practices, and solar and energy storage installation.

Barrier

Lack of insight into day-to-day energy use and operational impact on energy costs; no interval data available from utility.

Project Description

Dylan Aerospace (“Dylan”) manufactures and assembles materials for the large commercial and military aircraft markets. In recent years, Dylan has expanded its capabilities and diversified its operations  through various business initiatives and technological investments. The Dylan team aimed to optimize its operations through energy use insights. The primary goal for the site was for Dylan to evaluate the  facility’s energy capacity and usage levels, and develop a long-term energy strategy. The team planned to invest in new equipment that would allow it to increase production and revenue significantly, but was not sure if the existing energy capacity could support the new equipment, or if electrical upgrades would be necessary.

Solution

In partnership with Iteros, Elkor Technologies configured its revenue-grade energy meters with Iteros’ cloud-based monitoring software to provide Dylan with an all-in-one energy data collection and  visualization solution. The meters were installed on the manufacturing and operations portions of Dylan’s power system to monitor and benchmark real-time energy data.

Within minutes of the meters being installed, Iteros’ software began compiling the data collected and displaying it through the software’s interface. As the illustrations began to take shape, Dylan and Iteros evaluated usage trends throughout the system. Diving deeper into the data collected over time, two deficiencies were uncovered: a subpar power factor within the manufacturing system, and a new air compressor operating more frequently than it should. The trends also signaled that equipment remained on during unoccupied periods, resulting in higher energy costs. These insights allowed Dylan to
immediately begin making operational adjustments to lower energy costs claiming 15% in immediate savings. The data review also discovered spare capacity available in the system to support the installation of recently purchased manufacturing equipment.

This energy monitoring platform provides utility customers with a turn-key solution to access real-time, trending, and historical energy consumption data. Customers can gain insight into their energy usage, identify areas to improve energy efficiency, and validate operational adjustments within their system. It also helps develop long-term energy strategies, including system expansion and integration of sustainable technologies, as well as compliance with ASHRAE 90.1 2013, California’s Title 24 Energy Standard, and measurement and verification standards for energy efficiency measures.