Waterbury Plating & Paint Company

Waterbury Plating & Paint Company

WATERBURY, CONNECTICUT

Waterbury Plating & Paint Company is a division of Northeast Metal Works, the largest provider of metal plating, finishing and stamping in the Northeast. The facility is 60,000 square feet and runs three shifts.

CHALLENGE

It took six months to develop a comprehensive project that addressed all of the opportunities facility wide for energy efficiency improvements. All mechanical systems were thoroughly inspected, and ESC worked closely with management to develop a viable solution that addressed their goals of reducing energy consumption and improving plant performance.

SOLUTION

Over 260 LED lighting fixtures with occupancy and dimming controls were installed. A total of 23 steam traps were identified and replaced, and a management system was implemented that utilized slate tags to support future inspection and maintenance. Approximately 2,000 linear feet of  fiberglass pipe insulation for steam and condensate piping was incorporated, to include the fabrication and installation of 110 removable insulation blankets on steam pipe valves and boiler equipment and PVC jackets on piping located near the plating machines to protect the insulation from corrosive chemicals.

RESULTS

ESC delivered a turn-key project that secured an Eversource Energy incentive of nearly $250,000, which represents 72% of the total project cost and was financed with a low interest energy loan with no capital outlay, which generates net positive cash flow of over $3,000 a month that can be used for operating capital. The upgrades will save Waterbury Plating $64,489 annually on gas and electric expenses and an estimated $650,000 over the life of the equipment, while offering improved light quality and comfort for the employees and help achieve their sustainability goals.