Automatic Glass Seaming System Installation

Project Summary

The plant evaluated in this project runs a window glass tempering operation that operates twenty-four hours a day, five days a week, fifty-two weeks a year. The plant has two furnaces: the main CBHF furnace is newer and has variable frequency drives (VFDs), cooling fans, and an advanced control system; the second furnace is an older and less efficient Mroczek furnace, only used when demand increases. Lockheed Martin Energy's Heavy Industry Energy Efficiency Program (HIEEP) performed a site audit to identify potential energy savings, and found opportunities through automating the glass seaming operation.

The first Energy Efficiency Measure (EEM) was designed to remove production bottlenecking through automating the operation on the more efficient furnace. The energy audit noted that the manual glass seaming operation was restricting the CBHF furnace from producing as much tempered glass as it allowed for. Most of the glass seamed at this plant was in square and rectangular shapes, which was most suitable for the automation process. With an automated glass seaming operation for the square and rectangular pieces of glass, the rejected glass product was reduced by about 2%. With the reduction in rejected glass and the increase in production, the overall production of the CBHF furnace increased by 18%. This allowed for the CBHF furnace to run more of the plants production, reducing the hours of operation of the Mroczek furnace. Lockheed Martin Energy engineers adhered to IPMVP Option C to verify the energy savings for the project.

Prior to the installation of this Energy Efficiency Measure, the Mroczek furnace was producing an average of 26% of the plant's glass production. This 18% increase in the CBHF furnace production reduced the Mroczek furnace production to 12.7% of the plant's total production, reducing the operating hours of the Mroczek furnace by 51.2%. This measure saved 537,673 kWh of energy. The project cost was $120,746, and the incentive was $43,014, resulting in a net cost of $77,732. The energy cost savings were $77,963, allowing for a simple payback period of 1 year.

Project Team

PGE Logo
Program Pacific Gas and
Electric Company
Lockheed Martin Logo
Lockheed Martin Energy
Heavy Industry Energy Efficiency

Goals

Identify and quantify cost-effective energy savings

Strategies

Reduce the production hours of the less efficient furnace by automating the more efficient production system

Benefits:

Energy Savings

537,673 kWh

Equipment Installed

Automated Glass Seaming System

Financial Analysis:

Annual Cost Savings $77,963

Net Project Cost

$77,732

Project Incentive

$43,014

Simple Payback

1 year

It is our objective to assist PG&E heavy industry customers in:

Improve product quality and production rate
Identify process-focused energy efficiency improvements and other opportunities
Facilitate electricity and natural-gas energy efficiency equipment and demand reduction upgrades
 
Reduce operating costs per unit of product
Reduce waste, pollutants, and Green House Gas emissions
 

Increased production efficiency = Lower production costs = Increased profits