US Button Corporation

US Button Corporation

PUTNAM, CONNECTICUT

US Button / Emsig Manufacturing, founded in 1928 and managed by third and fourth generation family members, produces high-quality buttons that are distributed worldwide. The company’s facility in Putnam, CT employs more than 80 people, and has approximately 90,000 square feet of space, including production areas, meeting spaces and offices.

CHALLENGE

US Button was looking to improve energy costs and equipment reliability without shutting down operations. After learning of ESC’s expertise as a customer liaison to Eversource Energy, US Button hired ESC to make major mechanical and lighting upgrades to an active manufacturing facility with approximately 60 employees that operates 5 days per week in two shifts from 6:00 am to 11:15 pm.

SOLUTION

Despite the constraints of working in an active manufacturing facility, ESC completed many upgrades. Highlights of the work included the design and installation of two dozen custom removable insulation jacketed for steam system pipes and components to prevent heat loss, the upgrade of over 1,000 existing lighting fixtures to efficient LED retrofits throughout the facility to brighten work spaces, and the replacement of an old compressor with two compact, highly efficient compressors to reduce energy consumption and motor noise. An ultrasonic air study was performed to identify and repair air leaks.

RESULTS

All measures that were implemented were eligible for utility incentives and completed over a span of three months with no interruption to production. US Button secured a $222,500 utility incentive to assist in the funding of their capital improvements. With these energy efficiency measures, US Button has decreased its annual utility costs by one third.