PepsiCo has utilized the compressed air technical support of Air Power USA for over 10 years. We have found their services to be very professional and of great benefit. Air Power USA energy teams have conducted full compressed air system audits in PepsiCo and supplier facilities with total projected compressed air energy savings in excess of $2M/year and an average energy reduction of 40% to produce the compressed air. Average simple payback was less than 18 months with many of the improvement projects qualifying for utility rebate program incentives thereby shortening the actual ROI. These utility projects were all third party measured confirming accurate data collection and analysis by Air Power. Air Power has also worked closely with PepsiCo in development and delivery of training webinars, workshop presentations and annual summit exhibition presence.
Air Power USA has performed well at more than 40 of our plants in North America. By implementing 14 of the audit recommendations in one plant, we cut our electric bill by $400,000 and our electric demand by more than 500 kW. As part of another energy project, the Air Power team reduced our energy cost by a similar amount at our Madera plant served by PG&E. Savings levels projected in the Madera audit report were within 1% of the actual savings level achieved. We have confidence that Air Power USA will deliver the energy savings projected in its audits.
This Industry Recognition Award is to acknowledge your hard work, dedication and many hours of voluntary effort in developing the curriculums and implementation strategy for the Compressed Air Challenge Training Program.
We have implemented the program where we are running only two of the four air compressors when we run the mill and packaging lines. This is phenomenal when you consider that it took up to four compressors in the past to do the same thing.
With the audit by Air Power USA, we have reduced our energy bill for compressed air by 74%. Our new compressor that was recommended in the audit is performing great. Whenever we have had follow-up questions about any compressed air issues, Air Power‘s staff are always helpful in getting us the answer. We were so pleased with their program that we helped recruit another plant to participate.
The review of our compressed air systems by Air Power USA has been a great help to Air Industries. We are under a “supplier mandate” to reduce our production cost by 10% over the next three years. The savings of more than $100,000 that we gain from improving our compressed air system (about half of our current cost) will help us achieve the goal. Quite frankly, without Air Power efforts, it is unlikely we would have captured any of these savings.
Your audit has already resulted in substantial improvements in our compressed air systems. New dryers have been specified for the actual operating conditions. The old dryers were not designed for the conditions in which they were being used. Also, the distribution piping has been revised and the storage added. The projected energy savings is well into the hundreds of thousands of dollars.