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U.S. Department of Energy Energy Efficiency and Renewable Energy
IAC Field Managers

Full Assessment Recommendations Codes (ARC) List

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2. ENERGY MANAGEMENT 104,788
2.1 Combustion Systems 6,751
2.11 FURNACES, OVENS AND DIRECTLY FIRED OPERATIONS 1,268
2.111 Operations 317
2.1111 CONTROL PRESSURE ON STEAMER OPERATIONS 19
2.1112 HEAT OIL TO PROPER TEMPERATURE FOR GOOD ATOMIZATION 1
2.1113 REDUCE COMBUSTION AIR FLOW TO OPTIMUM 153
2.1114 LIMIT AND CONTROL SECONDARY COMBUSTION AIR IN FURNACE 20
2.1115 ELIMINATE COMBUSTIBLE GAS IN FLUE GAS 6
2.1116 IMPROVE COMBUSTION CONTROL CAPABILITY 105
2.1117 RELOCATE OVEN / FURNACE TO MORE EFFICIENT LOCATION 13
2.112 Hardware 421
2.1121 USE INSULATION IN FURNACES TO FACILITATE HEATING / COOLING 100
2.1122 RE-SIZE CHARGING OPENINGS OR ADD A MOVABLE DOOR ON EQUIPMENT 57
2.1123 INSTALL AUTOMATIC STACK DAMPER 255
2.1124 REPLACE DIRECT FIRED WITH STEAM HEAT 3
2.1125 CONVERT TO OXYFUEL BURNERS 6
2.113 Maintenance 530
2.1131 REPAIR FAULTY INSULATION IN FURNACES, BOILERS, ETC 229
2.1132 REPAIR FAULTY LOUVERS AND DAMPERS 6
2.1133 ADJUST BURNERS FOR EFFICIENT OPERATION 199
2.1134 ELIMINATE LEAKS IN COMBUSTIBLE GAS LINES 11
2.1135 REPAIR FURNACES AND OVEN DOORS SO THAT THEY SEAL EFFICIENTLY 85
2.12 BOILERS 3,634
2.121 Operation 416
2.1211 MOVE BOILER TO MORE EFFICIENT LOCATION 21
2.1212 OPERATE BOILERS ON HIGH FIRE SETTING 61
2.1213 DIRECT WARMEST AIR TO COMBUSTION INTAKE 334
2.122 Hardware 500
2.1221 REPLACE OBSOLETE BURNERS WITH MORE EFFICIENT ONES 145
2.1222 INSTALL TURBULATORS 148
2.1223 INSTALL SMALLER BOILER (INCREASE HIGH FIRE DUTY CYCLE) 55
2.1224 REPLACE BOILER 152
2.123 Maintenance 2,482
2.1231 ESTABLISH BURNER MAINTENANCE SCHEDULE FOR BOILERS 89
2.1232 KEEP BOILER TUBES CLEAN 108
2.1233 ANALYZE FLUE GAS FOR PROPER AIR/FUEL RATIO 2,285
2.124 Blowdown 236
2.1241 REDUCE EXCESSIVE BOILER BLOWDOWN 56
2.1242 MINIMIZE BOILER BLOWDOWN WITH BETTER FEEDWATER TREATMENT 28
2.1243 USE HEAT FROM BOILER BLOWDOWN TO PREHEAT BOILER FEED WATER 152
2.13 FUEL SWITCHING 1,849
2.131 Electric to Fossil Fuel 1,442
2.1311 REPLACE ELECTRICALLY-OPERATED EQUIPMENT WITH FOSSIL FUEL EQUIPMENT 1,442
2.132 Fossil Fuel to Electric 95
2.1321 REPLACE FOSSIL FUEL EQUIPMENT WITH ELECTRICAL EQUIPMENT 70
2.1322 USE ELECTRIC HEAT IN PLACE OF FOSSIL FUEL HEATING SYSTEM 23
2.1323 REPLACE GAS-FIRED ABSORPTION AIR CONDITIONERS WITH ELECTRIC UNITS 2
2.133 Alternate Fuel 274
2.1331 BURN A LESS EXPENSIVE GRADE OF FUEL 129
2.1332 CONVERT COMBUSTION EQUIPMENT TO BURN NATURAL GAS 77
2.1333 CONVERT COMBUSTION EQUIPMENT TO BURN OIL 19
2.1334 CONVERT OIL OR GAS BURNERS TO COMBUSTION OF COAL 3
2.1335 REPLACE GASOLINE WITH DIESEL, LPG, OR NATURAL GAS 13
2.1336 INSTALL EQUIPMENT TO UTILIZE WASTE FUEL 33
2.139 Miscellaneous 38
2.1391 REPLACE PURCHASED STEAM WITH ELECTRIC HEATING 1
2.1392 REPLACE PURCHASED STEAM WITH OTHER ENERGY SOURCE 25
2.1393 USE STEAM SPARGING OR INJECTIONS IN PLACE OF INDIRECT HEATING 8
2.1394 REPLACE STEAM JETS ON VACUUM SYSTEM WITH ELECTRIC MOTOR DRIVEN VACUUM PUMPS 4
2.2 Thermal Systems 15,636
2.21 STEAM 3,381
2.211 Traps 343
2.2111 INSTALL STEAM TRAP 23
2.2112 USE CORRECT SIZE STEAM TRAPS 3
2.2113 REPAIR OR REPLACE STEAM TRAPS 307
2.2114 SHUT OFF STEAM TRAPS ON SUPER HEATED STEAM LINES WHEN NOT IN USE 10
2.212 Condensate 711
2.2121 INCREASE AMOUNT OF CONDENSATE RETURNED 266
2.2122 INSTALL / REPAIR INSULATION ON CONDENSATE LINES 301
2.2123 INSULATE FEEDWATER TANK 92
2.2124 INSTALL DE-AERATOR IN PLACE OF CONDENSATE TANK 13
2.2125 REPLACE BAROMETRIC CONDENSERS WITH SURFACE CONDENSERS 0
2.2126 LOWER OPERATING PRESSURE OF CONDENSER (STEAM) 5
2.2127 FLASH CONDENSATE TO PRODUCE LOWER PRESSURE STEAM 20
2.2128 USE STEAM CONDENSATE FOR HOT WATER SUPPLY (NON-POTABLE) 14
2.213 Leaks and Insulation 2,045
2.2131 INSULATE STEAM / HOT WATER LINES 1,290
2.2132 REPAIR FAULTY INSULATION ON STEAM LINES 15
2.2133 REPAIR LEAKS IN LINES AND VALVES 429
2.2134 ELIMINATE LEAKS IN HIGH PRESSURE REDUCING STATIONS 1
2.2135 REPAIR AND ELIMINATE STEAM LEAKS 310
2.214 Distillation 5
2.2141 OPERATE DISTILLATION COLUMNS EFFICIENTLY 2
2.2142 UPGRADE DISTILLATION HARDWARE 3
2.215 Maintenance 56
2.2151 CLEAN STEAM COILS IN PROCESSING TANKS 1
2.2152 MAINTAIN STEAM JETS USED FOR VACUUM SYSTEM 3
2.2153 CLOSE OFF UNNEEDED STEAM LINES 52
2.216 Operations 194
2.2161 OPTIMIZE OPERATION OF MULTI-STAGE VACUUM STEAM JETS 4
2.2162 REDUCE EXCESS STEAM BLEEDING 29
2.2163 USE MINIMUM STEAM OPERATING PRESSURE 148
2.2164 TURN OFF STEAM TRACING DURING MILD WEATHER 11
2.2165 SUBSTITUTE AIR FOR STEAM TO ATOMIZE OIL 2
2.219 Miscellaneous 27
2.2191 SUBSTITUTE HOT PROCESS FLUIDS FOR STEAM 20
2.2192 USE HEAT EXCHANGE FLUIDS INSTEAD OF STEAM IN PIPELINE TRACING SYSTEMS 7
2.22 HEATING 231
2.221 Operation 158
2.2211 USE OPTIMUM TEMPERATURE 103
2.2212 USE MINIMUM SAFE OVEN VENTILATION 55
2.222 Hardware 73
2.2221 USE IMMERSION HEATING IN TANKS, MELTING POTS, ETC 18
2.2222 CONVERT LIQUID HEATERS FROM UNDERFIRING TO IMMERSION OR SUBMERSION HEATING 7
2.2223 ENHANCE SENSITIVITY OF TEMPERATURE CONTROL AND CUTOFF 48
2.23 HEAT TREATING 85
2.231 General 85
2.2311 HEAT TREAT PARTS ONLY TO REQUIRED SPECIFICATIONS OR STANDARDS 13
2.2312 MINIMIZE NON-ESSENTIAL MATERIAL IN HEAT TREATMENT PROCESS 17
2.2313 USE BATCH FIRING WITH KILN "FURNITURE" SPECIFICALLY DESIGNED 3
2.2314 REPLACE HEAT TREATING OVEN WITH MORE EFFICIENT UNIT 52
2.24 HEAT RECOVERY 5,892
2.241 Flue Gas Recuperation 1,467
2.2411 USE WASTE HEAT FROM HOT FLUE GASES TO PREHEAT COMBUSTION AIR 1,030
2.2412 USE FLUE GAS HEAT TO PREHEAT BOILER FEEDWATER 434
2.2413 USE HOT FLUE GASES TO PREHEAT WASTES FOR INCINERATOR BOILER 3
2.242 Flue Gas - Other Uses 471
2.2421 INSTALL WASTE HEAT BOILER TO PROVIDE DIRECT POWER 10
2.2422 USE WASTE HEAT FROM HOT FLUE GASES TO GENERATE STEAM 44
2.2423 INSTALL WASTE HEAT BOILER TO PRODUCE STEAM 10
2.2424 USE HEAT IN FLUE GASES TO PREHEAT PRODUCTS OR MATERIALS 110
2.2425 USE FLUE GASES TO HEAT PROCESS OR SERVICE WATER 89
2.2426 USE WASTE HEAT FROM FLUE GASES TO HEAT SPACE CONDITIONING AIR 103
2.2427 USE WASTE HEAT FROM HOT FLUE GASES TO PREHEAT INCOMING FLUIDS 68
2.2428 USE FLUE GASES IN RADIANT HEATER FOR SPACE HEATING, OVENS, ETC 37
2.243 Heat Recovery from Specific Equipment 2,776
2.2431 RECOVER HEAT FROM TRANSFORMERS 9
2.2432 RECOVER HEAT FROM OVEN EXHAUST / KILNS 288
2.2433 RECOVER HEAT FROM ENGINE EXHAUSTS 16
2.2434 RECOVER HEAT FROM AIR COMPRESSOR 1,455
2.2435 RECOVER HEAT FROM COMPRESSED AIR DRYERS 12
2.2436 RECOVER HEAT FROM REFRIGERATION CONDENSERS 125
2.2437 RECOVER WASTE HEAT FROM EQUIPMENT 871
2.244 Other Process Waste Heat 1,050
2.2441 PREHEAT BOILER MAKEUP WATER WITH WASTE PROCESS HEAT 131
2.2442 PREHEAT COMBUSTION AIR WITH WASTE HEAT 167
2.2443 RE-USE OR RECYCLE HOT OR COLD PROCESS EXHAUST AIR 274
2.2444 USE HOT PROCESS FLUIDS TO PREHEAT INCOMING PROCESS FLUIDS 194
2.2445 RECOVER HEAT FROM EXHAUSTED STEAM 59
2.2446 RECOVER HEAT FROM HOT WASTE WATER 130
2.2447 HEAT WATER WITH EXHAUST HEAT 95
2.249 Miscellaneous 128
2.2491 USE COOLING AIR WHICH COOLS HOT WORK PIECES FOR SPACE HEATING 32
2.2492 USE "HEAT WHEEL" OR OTHER HEAT EXCHANGER TO CROSS-EXCHANGE BUILDING EXHAUST AIR WITH MAKE-UP AIR 78
2.2493 USE RECOVERED HEAT FROM LIGHTING FIXTURES FOR USEFUL PURPOSE 0
2.2494 RECOVER HEAT IN DOMESTIC HOT WATER GOING TO DRAIN 14
2.2495 USE EXHAUST HEAT FROM BUILDING FOR SNOW AND ICE REMOVAL 2
2.2496 HEAT SERVICE HOT WATER WITH AIR CONDITIONING EQUIPMENT 2
2.25 HEAT CONTAINMENT 4,587
2.251 Insulation 4,136
2.2511 INSULATE BARE EQUIPMENT 3,367
2.2512 INCREASE INSULATION THICKNESS 232
2.2513 COVER OPEN TANKS WITH FLOATING INSULATION 178
2.2514 COVER OPEN TANKS 259
2.2515 USE OPTIMUM THICKNESS INSULATION 80
2.2516 USE ECONOMIC THICKNESS OF INSULATION FOR LOW TEMPERATURES 20
2.252 Isolation 206
2.2521 ISOLATE STEAM LINES TO AVOID HEATING AIR CONDITIONED AREAS 9
2.2522 ISOLATE HOT OR COLD EQUIPMENT 78
2.2523 REDUCE INFILTRATION TO REFRIGERATED AREAS; ISOLATE HOT EQUIPMENT FROM REFRIGERATED AREAS 91
2.2524 AVOID COOLING OF PROCESS STREAMS OR MATERIALS THAT MUST SUBSEQUENTLY BE HEATED 14
2.2525 ELIMINATE COOLING OF PROCESS STREAMS WHICH SUBSEQUENTLY MUST BE HEATED AND VICE VERSA 14
2.253 Infiltration 245
2.2531 RE-SIZE CHARGING OPENINGS OR ADD MOVABLE COVER OR DOOR 166
2.2532 USE ONLY AMOUNT OF AIR NECESSARY TO PREVENT EXPLOSION HAZARD 72
2.2533 REPLACE AIR CURTAIN DOORS WITH SOLID DOORS 7
2.26 COOLING 1,401
2.261 Cooling Towers 455
2.2611 MODERATE COOLING TOWER OUTLET TEMPERATURE 42
2.2612 USE COOLING TOWER WATER INSTEAD OF REFRIGERATION 103
2.2613 USE ANTIFREEZE IN COOLING TOWERS TO ALLOW WINTER USE 0
2.2614 USE COOLING TOWER OR ECONOMIZER TO REPLACE CHILLER COOLING 300
2.2615 CLEAN CONDENSER TUBES 10
2.262 Chillers and Refrigeration 781
2.2621 MODIFY REFRIGERATION SYSTEM TO OPERATE AT A LOWER PRESSURE 249
2.2622 REPLACE EXISTING CHILLER WITH HIGH EFFICIENCY MODEL 133
2.2623 MINIMIZE CONDENSER COOLING WATER TEMPERATURE 33
2.2624 USE COLD WASTE WATER TO COOL CHILLER FEED WATER 11
2.2625 CHILL WATER TO THE HIGHEST TEMPERATURE POSSIBLE 109
2.2626 AVOID FROST FORMATION ON EVAPORATORS 19
2.2627 USE MULTIPLE-EFFECT EVAPORATORS 5
2.2628 UTILIZE A LESS EXPENSIVE COOLING METHOD 222
2.269 Miscellaneous 165
2.2691 SHUT OFF COOLING IF COLD OUTSIDE AIR WILL COOL PROCESS 62
2.2692 USE OUTSIDE COLD WATER SOURCE AS A SUPPLY OF COOLING WATER 34
2.2693 USE WASTE HEAT STEAM FOR ABSORPTION REFRIGERATION 13
2.2694 USE HIGHEST TEMPERATURE FOR CHILLING OR COLD STORAGE 37
2.2695 USE CASCADE SYSTEM OF RECIRCULATING DURING COLD WEATHER TO AVOID SUB-COOLING 3
2.2696 USE EXCESS COLD PROCESS FLUID FOR INDUSTRIAL COOLING NEEDS 16
2.27 DRYING 59
2.271 Use of Air 59
2.2711 UTILIZE OUTSIDE AIR INSTEAD OF CONDITIONED AIR FOR DRYING 59
2.3 Electrical Power 4,968
2.31 DEMAND MANAGEMENT 2,497
2.311 Thermal Energy Storage 46
2.3111 HEAT WATER DURING OFF-PEAK PERIODS AND STORE FOR LATER USE 7
2.3112 STORE HEATED/ COOLED WATER FOR USE DURING PEAK DEMAND PERIODS 11
2.3113 MAKE ICE DURING OFF PEAK HOURS FOR COOLING 28
2.313 Scheduling 1,894
2.3131 RESCHEDULE PLANT OPERATIONS OR REDUCE LOAD TO AVOID PEAKS 1,256
2.3132 RECHARGE BATTERIES ON DURING OFF-PEAK DEMAND PERIODS 337
2.3133 CONSIDER THREE OR FOUR DAYS AROUND-THE-CLOCK OPERATION RATHER THAN ONE OR TWO SHIFTS PER DAY 8
2.3134 SHIFT FROM DAYTIME TO NIGHTTIME OPERATION 108
2.3135 SCHEDULE ROUTINE MAINTENANCE DURING NON-OPERATING PERIODS 21
2.3136 OVERLAP CUSTODIAL SERVICES WITH NORMAL DAY HOURS 17
2.3137 USE POWER DURING OFF-PEAK PERIODS 147
2.319 Miscellaneous 557
2.3191 USE DEMAND CONTROLLER OR LOAD SHEDDER 507
2.3192 USE FOSSIL FUEL POWERED GENERATOR DURING PEAK DEMAND PERIODS 50
2.32 POWER FACTOR 1,839
2.321 General 1,839
2.3211 USE POWER FACTOR CONTROLLERS 429
2.3212 OPTIMIZE PLANT POWER FACTOR 1,410
2.33 GENERATION OF POWER 66
2.331 DC 26
2.3311 REPLACE DC EQUIPMENT WITH AC EQUIPMENT 9
2.3312 INSTALL EFFICIENT RECTIFIERS 17
2.332 AC 40
2.3321 USE STEAM PRESSURE REDUCTION TO GENERATE POWER 28
2.3322 USE EXISTING DAM TO GENERATE ELECTRICITY 11
2.3323 INSTALL EMISSIONS CONTROLS TO INCREASE CAPACITY 1
2.34 COGENERATION 435
2.341 General 435
2.3411 REPLACE ELECTRIC MOTORS WITH BACK PRESSURE STEAM TURBINES AND USE EXHAUST STEAM FOR PROCESS HEAT 15
2.3412 USE WASTE HEAT TO PRODUCE STEAM TO DRIVE A STEAM TURBINE-GENERATOR 64
2.3413 BURN FOSSIL FUEL TO PRODUCE STEAM TO DRIVE A STEAM TURBINE-GENERATOR AND USE STEAM EXHAUST FOR HEAT 45
2.3414 BURN WASTE TO PRODUCE STEAM TO DRIVE A STEAM TURBINE GENERATOR SET AND USE STEAM EXHAUST FOR HEAT 46
2.3415 USE A FOSSIL FUEL ENGINE TO COGENERATE ELECTRICITY OR MOTIVE POWER; AND UTILIZE HEAT 184
2.3416 USE COMBINED CYCLE GAS TURBINE GENERATOR SETS WITH WASTE HEAT BOILERS CONNECTED TO TURBINE EXHAUST 43
2.3417 USE WASTE HEAT WITH A CLOSED-CYCLE GAS TURBINE-GENERATOR SET TO COGENERATE ELECTRICITY AND HEAT 38
2.35 TRANSMISSION 131
2.351 Transformers 120
2.3511 USE PLANT OWNED TRANSFORMERS OR LEASE TRANSFORMERS 82
2.3512 DE-ENERGIZE EXCESS TRANSFORMER CAPACITY 34
2.3513 CONSIDER POWER LOSS AS WELL AS INITIAL LOADS AND LOAD GROWTH IN DOWN-SIZING TRANSFORMERS 4
2.352 Conductor Size 11
2.3521 REDUCE LOAD ON ELECTRICAL CONDUCTOR TO REDUCE HEATING LOSSES 5
2.3522 INCREASE ELECTRICAL CONDUCTOR SIZE TO REDUCE DISTRIBUTION LOSSES 6
2.4 Motor Systems 34,427
2.41 MOTORS 12,430
2.411 Operation 4,087
2.4111 UTILIZE ENERGY-EFFICIENT BELTS AND OTHER IMPROVED MECHANISMS 4,005
2.4112 INSTALL SOFT-START TO ELIMINATE NUISANCE TRIPS 54
2.4113 INSTALL MOTOR VOLTAGE CONTROLLER ON LIGHTLY LOADED MOTORS 28
2.413 Hardware 5,394
2.4131 REPLACE OVER-SIZE MOTORS AND PUMPS WITH OPTIMUM SIZE 225
2.4132 SIZE ELECTRIC MOTORS FOR PEAK OPERATING EFFICIENCY 61
2.4133 USE MOST EFFICIENT TYPE OF ELECTRIC MOTORS 5,083
2.4134 REPLACE ELECTRIC MOTOR WITH FOSSIL FUEL ENGINE 25
2.414 Motor System Drives 2,439
2.4141 USE MULTIPLE SPEED MOTORS OR AFD FOR VARIABLE PUMP, BLOWER AND COMPRESSOR LOADS 1,724
2.4142 USE ADJUSTABLE FREQUENCY DRIVE TO REPLACE MOTOR-GENERATOR SET 123
2.4143 USE ADJUSTABLE FREQUENCY DRIVE TO REPLACE THROTTLING SYSTEM 249
2.4144 USE ADJUSTABLE FREQUENCY DRIVE TO REPLACE MECHANICAL DRIVE 339
2.4145 INSTALL ISOLATION TRANSFORMER ON ADJUSTABLE FREQUENCY DRIVE 4
2.415 Motor Maintenance/Repair 510
2.4151 DEVELOP A REPAIR/REPLACE POLICY 339
2.4152 USE ONLY CERTIFIED MOTOR REPAIR SHOPS 0
2.4153 AVOID EMERGENCY REWIND OF MOTORS 2
2.4154 AVOID REWINDING MOTORS MORE THAN TWICE 9
2.4155 STANDARDIZE MOTOR INVENTORY 4
2.4156 ESTABLISH A PREVENTATIVE MAINTENANCE PROGRAM 37
2.4157 ESTABLISH A PREDICTIVE MAINTENANCE PROGRAM 119
2.42 AIR COMPRESSORS 19,242
2.422 Hardware 6,253
2.4221 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 4,913
2.4222 INSTALL ADEQUATE DRYERS ON AIR LINES TO ELIMINATE BLOWDOWN 95
2.4223 INSTALL DIRECT ACTING UNITS IN PLACE OF COMPRESSED AIR PRESSURE SYSTEM IN SAFETY SYSTEM 26
2.4224 UPGRADE CONTROLS ON COMPRESSORS 516
2.4225 INSTALL COMMON HEADER ON COMPRESSORS 45
2.4226 USE / PURCHASE OPTIMUM SIZED COMPRESSOR 601
2.4227 USE COMPRESSOR AIR FILTERS 57
2.423 Operations 12,989
2.4231 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED 3,920
2.4232 ELIMINATE OR REDUCE COMPRESSED AIR USED FOR COOLING, AGITATING LIQUIDS, MOVING PRODUCT, OR DRYING 1,199
2.4233 ELIMINATE PERMANENTLY THE USE OF COMPRESSED AIR 202
2.4234 COOL COMPRESSOR AIR INTAKE WITH HEAT EXCHANGER 46
2.4235 REMOVE OR CLOSE OFF UNNEEDED COMPRESSED AIR LINES 136
2.4236 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 7,419
2.4237 SUBSTITUTE COMPRESSED AIR COOLING WITH WATER OR AIR COOLING 37
2.4238 DO NOT USE COMPRESSED AIR FOR PERSONAL COOLING 30
2.43 OTHER EQUIPMENT 2,755
2.431 Operations 1,539
2.4311 RECOVER MECHANICAL ENERGY 24
2.4312 IMPROVE LUBRICATION PRACTICES 576
2.4313 PROVIDE PROPER MAINTENANCE OF MOTOR DRIVEN EQUIPMENT 13
2.4314 USE SYNTHETIC LUBRICANT 926
2.432 Hardware 1,216
2.4321 UPGRADE OBSOLETE EQUIPMENT 141
2.4322 USE OR REPLACE WITH ENERGY EFFICIENT SUBSTITUTES 678
2.4323 USE OPTIMUM SIZE AND CAPACITY EQUIPMENT 264
2.4324 REPLACE HYDRAULIC / PNEUMATIC EQUIPMENT WITH ELECTRIC EQUIPMENT 119
2.4325 UPGRADE CONVEYORS 14
2.5 Industrial Design 442
2.51 SYSTEMS 442
2.511 Thermal 71
2.5111 CONVERT FROM INDIRECT TO DIRECT FIRED SYSTEMS 38
2.5112 USE CONTINUOUS EQUIPMENT WHICH RETAINS PROCESS HEATING CONVEYORS WITHIN THE HEATED CHAMBER 2
2.5113 USE DIRECT FLAME IMPINGEMENT OR INFRARED PROCESSING FOR CHAMBER TYPE HEATING 15
2.5114 USE SHAFT TYPE FURNACES FOR PREHEATING INCOMING MATERIAL 2
2.5115 REPOSITION OVEN WALLS TO REDUCE HEATED SPACE 10
2.5116 USE EXCESS COLD PROCESS FLUID FOR INDUSTRIAL COOLING NEEDS 2
2.5117 CONVERT TO INDIRECT TEMPERATURE CONTROL SYSTEM 2
2.512 Mechanical 141
2.5121 REDESIGN FLOW TO MINIMIZE MASS TRANSFER LENGTH 25
2.5122 REPLACE HIGH RESISTANCE DUCTS, PIPES, AND FITTINGS 16
2.5123 REDUCE FLUID FLOW RATES 80
2.5124 USE GRAVITY FEEDS WHEREVER POSSIBLE 6
2.5125 SIZE AIR HANDLING GRILLS/ DUCT/S COILS TO MINIMIZE AIR RESISTANCE 14
2.519 Miscellaneous 230
2.5191 MODIFY DYE BECK 23
2.5192 MODIFY TEXTILE DRYERS 30
2.5193 CONVERT FROM BATCH TO CONTINUOUS OPERATION 2
2.5194 REDESIGN PROCESS 133
2.5195 CHANGE PRODUCT DESIGN TO REDUCE ENERGY REQUIREMENTS 24
2.5196 USE SMALL NUMBER OF HIGH OUTPUT UNITS INSTEAD OF MANY SMALL INEFFICIENT UNITS 18
2.5197 AVOID ELECTRICALLY-POWERED ANIMATED DISPLAYS 0
2.6 Operations 5,434
2.61 MAINTENANCE 510
2.612 General 510
2.6121 REDUCE HOT WATER TEMPERATURE TO THE MINIMUM REQUIRED 317
2.6122 ADJUST VENTS TO MINIMIZE ENERGY USE 30
2.6123 REMOVE UNNEEDED SERVICE LINES TO ELIMINATE POTENTIAL LEAKS 6
2.6124 ESTABLISH EQUIPMENT MAINTENANCE SCHEDULE 76
2.6125 KEEP EQUIPMENT CLEAN 30
2.6126 KEEP SOLID FUELS / RAW MATERIALS DRY 8
2.6127 MAINTAIN AIR FILTERS BY CLEANING OR REPLACEMENT 43
2.62 EQUIPMENT CONTROL 4,924
2.621 Equipment Use Reduction 2,942
2.6211 CONSERVE ENERGY BY EFFICIENT USE OF VENDING MACHINES 315
2.6212 TURN OFF EQUIPMENT DURING BREAKS, REDUCE OPERATING TIME 926
2.6213 TURN OFF STEAM / HOT WATER LINES LEADING TO SPACE HEATING UNITS 14
2.6214 SHUT OFF PILOTS IN STANDBY EQUIPMENT 127
2.6215 SHUT OFF AIR CONDITIONING IN WINTER HEATING SEASON 8
2.6216 SHUT OFF COOLING WATER WHEN NOT REQUIRED 31
2.6217 SHUT OFF ALL LABORATORY FUME HOODS WHEN NOT IN USE 16
2.6218 TURN OFF EQUIPMENT WHEN NOT IN USE 1,505
2.622 Equipment Scheduling 365
2.6221 USE MOST EFFICIENT EQUIPMENT AT IT'S MAXIMUM CAPACITY AND LESS EFFICIENT EQUIPMENT ONLY WHEN NECESSARY 269
2.6222 USE DRYING OVEN (BATCH TYPE) ON ALTERNATE DAYS OR OTHER OPTIMUM SCHEDULE TO RUN EQUIPMENT WITH FULL LOADS 60
2.6223 SCHEDULE USE OF ELEVATORS TO CONSERVE ENERGY 10
2.6224 SCHEDULE BAKING TIMES OF SMALL AND LARGE COMPONENTS 14
2.6225 ELIMINATE THIRD SHIFT 7
2.6226 OPTIMIZE FILTRATION CLEANING / REPLACEMENT TO MINIMIZE AIR RESISTANCE 5
2.623 Equipment Automation 1,482
2.6231 UTILIZE CONTROLS TO OPERATE EQUIPMENT ONLY WHEN NEEDED 543
2.6232 INSTALL SET-BACK TIMERS 939
2.624 Load Reduction 135
2.6241 REDUCE TEMPERATURE OF PROCESS EQUIPMENT WHEN ON STANDBY 35
2.6242 MINIMIZE OPERATION OF EQUIPMENT MAINTAINED IN STANDBY CONDITION 100
2.7 Building and Grounds 34,537
2.71 LIGHTING 24,430
2.711 Level 1,893
2.7111 REDUCE ILLUMINATION TO MINIMUM NECESSARY LEVELS 1,747
2.7112 REDUCE EXTERIOR ILLUMINATION TO MINIMUM SAFE LEVEL 146
2.712 Operation 1,924
2.7121 UTILIZE DAYLIGHT WHENEVER POSSIBLE IN LIEU OF ARTIFICIAL LIGHT 485
2.7122 DISCONNECT BALLASTS 308
2.7123 KEEP LAMPS AND REFLECTORS CLEAN 183
2.7124 MAKE A PRACTICE OF TURNING OFF LIGHTS WHEN NOT NEEDED 948
2.713 Controls 4,899
2.7131 ADD AREA LIGHTING SWITCHES 149
2.7132 INSTALL TIMERS ON LIGHT SWITCHES IN LITTLE USED AREAS 223
2.7133 USE SEPARATE SWITCHES ON PERIMETER LIGHTING WHICH MAY BE TURNED OFF WHEN NATURAL LIGHT IS AVAILABLE 199
2.7134 USE PHOTOCELL CONTROLS 760
2.7135 INSTALL OCCUPANCY SENSORS 3,568
2.714 Hardware 15,714
2.7141 LOWER LIGHT FIXTURES IN HIGH CEILING AREAS 116
2.7142 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 11,394
2.7143 USE MORE EFFICIENT LIGHT SOURCE 3,415
2.7144 INSTALL SPECTRAL REFLECTORS / DELAMP 426
2.7145 INSTALL SKYLIGHTS 363
2.72 SPACE CONDITIONING 6,589
2.721 Maintenance 84
2.7211 CLEAN AND MAINTAIN REFRIGERANT CONDENSERS AND TOWERS 43
2.7212 INSTALL OR UPGRADE INSULATION ON HVAC DISTRIBUTION SYSTEMS 41
2.722 Operation 2,006
2.7221 LOWER TEMPERATURE DURING THE WINTER SEASON AND VICE-VERSA 609
2.7222 AIR CONDITION ONLY SPACE IN USE 167
2.7223 CONDITION SMALLEST SPACE NECESSARY 83
2.7224 REDUCE SPACE CONDITIONING DURING NON-WORKING HOURS 569
2.7225 CLOSE OUTDOOR AIR DAMPERS DURING WARM-UP / COOL-DOWN PERIODS 9
2.7226 USE COMPUTER PROGRAMS TO OPTIMIZE HVAC PERFORMANCE 419
2.7227 USE WATER ON AIR CONDITIONING EXCHANGER TO IMPROVE HEAT TRANSFER AND INCREASE AIR CONDITIONER EFFICIENCY 19
2.7228 AVOID INTRODUCING HOT, HUMID, OR DIRTY AIR INTO HVAC SYSTEM 131
2.723 Hardware - Heating / Cooling 1,132
2.7231 USE RADIANT HEATER FOR SPOT HEATING 513
2.7232 REPLACE EXISTING HVAC UNIT WITH HIGH EFFICIENCY MODEL 442
2.7233 USE PROPERLY DESIGNED AND SIZED HVAC EQUIPMENT 134
2.7234 USE HEAT PUMP FOR SPACE CONDITIONING 30
2.7235 INSTALL FOSSIL FUEL MAKE-UP AIR UNIT 13
2.724 Hardware - Air Circulation 1,181
2.7241 INSTALL OUTSIDE AIR DAMPER / ECONOMIZER ON HVAC UNIT 372
2.7242 CHANGE ZONE REHEAT COILS TO VARIABLE AIR VOLUME BOXES 13
2.7243 IMPROVE AIR CIRCULATION WITH DESTRATIFICATION FANS / OTHER METHODS 692
2.7244 REVISE SMOKE CLEANUP FROM OPERATIONS 22
2.7245 USE DIRECT AIR SUPPLY TO EXHAUST HOODS 82
2.725 Evaporation 105
2.7251 REDUCE AIR CONDITIONING LOAD BY EVAPORATING WATER FROM ROOF 54
2.7252 UTILIZE AN EVAPORATIVE AIR PRE-COOLER OR OTHER HEAT EXCHANGER IN AC SYSTEM 51
2.726 Controls 1,971
2.7261 INSTALL TIMERS AND/OR THERMOSTATS 1,915
2.7262 SEPARATE CONTROLS OF AIR HANDLERS FROM AC/ HEATING SYSTEMS 22
2.7263 LOWER COMPRESSOR PRESSURE THROUGH A/C SYSTEM MODIFICATION 14
2.7264 INTERLOCK HEATING AND AIR CONDITIONING SYSTEMS TO PREVENT SIMULTANEOUS OPERATION 20
2.727 Humidity Control 37
2.7271 REPLACE ELECTRIC REHEAT WITH HEAT PIPES 8
2.7272 INSTALL HEAT PIPES / RAISE COOLING SETPOINT 8
2.7273 INSTALL DESICCANT HUMIDITY CONTROL SYSTEM 21
2.729 Miscellaneous 73
2.7291 RESCHEDULE AND REARRANGE MULTIPLE-SOURCE HEATING SYSTEMS 30
2.7292 LOWER CEILING TO REDUCE CONDITIONED SPACE 34
2.7293 INSTALL DRY SPRINKLER SYSTEM OR OTHER METHOD TO REDUCE HEATING REQUIREMENTS 9
2.73 VENTILTION 744
2.731 General 744
2.7311 VENTILATION SYSTEM TO SHUT OFF WHEN ROOM IS NOT IN USE 35
2.7312 MINIMIZE USE OF OUTSIDE MAKE-UP AIR FOR VENTILATION EXCEPT WHEN USED FOR ECONOMIZER CYCLE 110
2.7313 RECYCLE AIR FOR HEATING, VENTILATION AND AIR CONDITIONING 111
2.7314 REDUCE VENTILATION AIR 318
2.7315 REDUCE BUILDING VENTILATION AIR TO MINIMUM SAFE LEVELS 106
2.7316 CENTRALIZE CONTROL OF EXHAUST FANS TO ENSURE THEIR SHUTDOWN, OR ESTABLISH PROGRAM TO ENSURE MANUAL SHUTDOWN 64
2.74 BUILDING ENVELOPE 2,774
2.742 Solar Loading 168
2.7421 REDUCE GLAZED AREAS IN BUILDINGS 31
2.7422 PLANT TREES OR SHRUBS NEAR WINDOWS TO SHIELD FROM SUNLIGHT 43
2.7423 REDUCE HEAT GAIN BY WINDOW TINTING 17
2.7424 SHADE WINDOWS FROM SUMMER SUN 9
2.7425 CLEAN OR COLOR ROOF TO REDUCE SOLAR LOAD 68
2.744 Infiltration 1,712
2.7441 REPLACE BROKEN WINDOWS AND/OR WINDOW SASH 79
2.7442 KEEP DOORS AND WINDOWS SHUT WHEN NOT ON USE 129
2.7443 INSTALL AIR SEALS AROUND TRUCK LOADING DOCK DOORS 447
2.7444 CLOSE HOLES AND OPENINGS IN BUILDING SUCH AS BROKEN WINDOWS 212
2.7445 INSTALL WEATHER STRIPPING ON WINDOWS AND DOORS 318
2.7446 UTILIZE SENSORS CONTROLLING ROOF AND WALL OPENINGS 26
2.7447 INSTALL VINYL STRIP / HIGH SPEED / AIR CURTAIN DOORS 501
2.749 Miscellaneous 894
2.7491 INSULATE GLAZING, WALLS, CEILINGS, AND ROOFS 282
2.7492 USE PROPER THICKNESS OF INSULATION ON BUILDING ENVELOPE 346
2.7493 USE DOUBLE OR TRIPLE GLAZED WINDOWS TO MAINTAIN HIGHER RELATIVE HUMIDITY AND TO REDUCE HEAT LOSSES 18
2.7494 INSTALL STORM WINDOWS AND DOORS 151
2.7495 INSTALL REPLACEMENT DOORS 19
2.7496 INSTALL PARTITIONS TO REDUCE SIZE OF CONDITIONED SPACE 78
2.8 Ancillary Costs 2,368
2.81 ADMINISTRATIVE 2,287
2.811 Utility Costs 1,415
2.8111 CHECK FOR ACCURACY OF UTILITY METERS 51
2.8112 COMBINE UTILITY METERS 240
2.8113 PURCHASE GAS DIRECTLY FROM A CONTRACT GAS SUPPLIER 318
2.8114 CHANGE RATE SCHEDULES OR OTHER CHANGES IN UTILITY SERVICE 792
2.8115 BASE UTILITY CHARGES ON USAGE RATHER THAN AREA OCCUPIED 4
2.8116 CHECK FOR ACCURACY OF POWER METER 9
2.8117 INSTALL SUB-METERING EQUIPMENT 1
2.812 Fiscal 872
2.8121 APPLY FOR TAX-FREE STATUS FOR ENERGY PURCHASES 622
2.8122 USE UTILITY CONTROLLED POWER MANAGEMENT 19
2.8123 PAY UTILITY BILLS ON TIME 230
2.8124 Hire Energy Manager 1
2.82 SHIPPING, DISTRIBUTION, AND TRANSPORTATION 81
2.821 Shipping 19
2.8211 CONSOLIDATE FREIGHT SHIPMENTS AND/OR DELIVERIES 14
2.8212 REDUCE DELIVERY SCHEDULES 5
2.822 Vehicles 62
2.8221 CONSIDER INTERMEDIATE OR ECONOMY SIZE AUTOS / TRUCKS 3
2.8222 SIZE TRUCKS TO JOB 1
2.8223 ADD AIR SHIELDS TO TRUCKS TO INCREASE FUEL MILEAGE 28
2.8224 SHUT DOWN TRUCK ENGINES WHILE LOADING, UNLOADING, OR WAITING 0
2.8225 SCHEDULE REGULAR MAINTENANCE TO MAINTAIN TRUCK ENGINES 0
2.8226 INCREASE EFFICIENCY OF TRUCKS 15
2.8227 ADJUST / MAINTAIN FORK LIFT TRUCKS FOR MOST EFFICIENT OPERATION 15
2.9 Alternative Energy Usage 225
2.91 GENERAL 225
2.911 Solar 201
2.9111 USE SOLAR HEAT TO HEAT MAKE-UP AIR 19
2.9112 USE SOLAR HEAT TO HEAT WATER 52
2.9113 USE SOLAR HEAT FOR HEAT 11
2.9114 USE SOLAR HEAT TO MAKE ELECTRICTY 119
2.912 Wind Power 17
2.9121 INSTALL WIND POWERED ELECTRIC GENERATOR 17
2.913 Hydrogen 3
2.9131 INSTALL HYDROGEN FUEL CELL 3
2.914 Biofuels 4
2.9141 Install Anaerobic Digester 4
3. WASTE MINIMIZATION / POLLUTION PREVENTION 9,169
3.1 Operations 1,022
3.11 Procedures 929
3.111 Process Specific 6
3.1111 COVER INK CONTAINERS WHEN NOT IN USE 4
3.1112 USE DEDICATED PRESSES FOR EACH COLOR 0
3.1113 USE GLASS MARBLES TO RAISE FLUID LEVELS OF CHEMICALS TO THE BRIM TO REDUCE CONTACT WITH ATMOSPHERIC OXYGEN 0
3.1114 REUSE HIGH FERROUS METAL DUST AS RAW MATERIAL 0
3.1115 ORDER PAINT PIGMENTS IN PASTE FORM INSTEAD OF DRY POWDER TO ELIMINATE HAZARDOUS DUST WASTE 1
3.1116 REPAIR / UPGRADE GRATE CONVEYORS TO MINIMIZE LOSS OF COAL FINES 1
3.112 Material Application 13
3.1121 USE MORE EFFICIENT ADHESIVE APPLICATORS 12
3.1122 SWITCH FROM AUTOMATIC TO HAND APPLICATION 1
3.113 Stripping 3
3.1131 USE MECHANICAL STRIPPING METHODS 3
3.1132 USE CRYOGENIC STRIPPING 0
3.114 Scheduling 0
3.1141 SCHEDULE JOBS TO MINIMIZE THE NEED FOR CLEANUP (COLORS) 0
3.1142 SCHEDULE PRODUCTION RUNS TO MINIMIZE COLOR CHANGES 0
3.115 Desulfurization / Slag Management 4
3.1151 TREAT DESULFURIZATION SLAG IN A DEEP QUENCH TANK INSTEAD OF SPRAYING WATER ONTO AN OPEN PILE TO REDUCE AIR EMISSIONS 0
3.1152 USE HIGH QUALITY SCRAP (LOW SULFUR) TO REDUCE HAZARDOUS SLUDGE GENERATION 2
3.1153 ALTER PRODUCT REQUIREMENTS TO ELIMINATE UNNECESSARY USE OF DESULFURIZING AGENT (CALCIUM CARBIDE) 0
3.1154 USE AN ALTERNATIVE DESULFURIZING AGENT TO ELIMINATE HAZARDOUS SLAG FORMATION 2
3.116 Reduction / Elimination 194
3.1161 ELIMINATE/REDUCE AN OPERATION 104
3.1162 USE LESS WASTEFUL PACKAGING 59
3.1163 USE PLASTIC PALLETS INSTEAD OF WOOD 31
3.117 Product Specifications 61
3.1171 CHANGE PRODUCT SPECS 7
3.1172 REVISE RAW MATERIAL SPECS 12
3.1173 USE A DIFFERENT RAW MATERIAL 20
3.1174 USE A RECYCLED RAW MATERIAL 22
3.118 By-product Use 48
3.1181 ELIMINATE A BY-PRODUCT 12
3.1182 MAKE A NEW BY-PRODUCT 36
3.119 Miscellaneous 600
3.1191 CHANGE PROCEDURES / EQUIPMENT / OPERATING CONDITIONS 440
3.1192 REDUCE SCRAP PRODUCTION 145
3.1193 CONVERT FROM BATCH OPERATION TO CONTINUOUS PROCESSING 8
3.1194 USE AUTOMATIC FLOW CONTROL 6
3.1195 USE SILHOUETTE ENTRY COVER TO REDUCE EVAPORATION AREA 0
3.1196 MONITOR SOLUTIONS TO MAINTAIN SOLUTION STRENGTH 1
3.12 Waste Stream Contamination 93
3.122 Rinsing Strategies 23
3.1221 USE REACTIVE RINSING 3
3.1222 REDUCE WATER USE WITH COUNTER CURRENT RINSING 10
3.1223 USE FOG NOZZLES / SPRAY RINSING INSTEAD OF IMMERSION RINSING 3
3.1224 MECHANICALLY AND AIR AGITATE RINSE TANKS FOR COMPLETE MIXING 0
3.1225 USE A STILL RINSE AS THE INITIAL RINSING STAGE 0
3.1226 USE COUNTER CURRENT WASHING IN PHOTO PROCESSORS 0
3.1227 USE COUNTER-CURRENT RINSING TO REDUCE RINSE WATER VOLUME (GRAVURE) 7
3.124 Dragout Reduction 32
3.1241 SLOW INSERTION / WITHDRAWAL OF PARTS FROM DEGREASING TANK 1
3.1242 ALLOW DRAINAGE BEFORE WITHDRAWING OBJECT 7
3.1243 PRE-INSPECT PARTS TO PREVENT DRAG-IN OF SOLVENTS / CLEANERS 0
3.1244 REDUCE SOLUTION DRAG-OUT TO PREVENT SOLUTION LOSS 20
3.1245 EXTEND SOLUTION LIFE BY MINIMIZING DRAG-IN 2
3.1246 LOWER THE CONCENTRATION OF PLATING BATHS 0
3.1247 USE DRAG-OUT REDUCTION METHODS (GRAVURE)-SEE SURFACE COATING 2
3.129 Miscellaneous 38
3.1291 ELIMINATE PRACTICE OF MIXING WASTE STREAMS 25
3.1292 DEVELOP SEGREGATED SEWER SYSTEMS 3
3.1293 SEPARATE TREATMENTS FOR EACH TYPE OF SOLUTION AND RECYCLE 8
3.1294 SEGREGATE SPENT SOLVENTS AND REUSE IN SUBSEQUENT WASHINGS 1
3.1295 USE SQUEEGEES TO PREVENT CHEMICAL CARRY-OVER 0
3.1296 AVOID CONTAMINATION OF SCRAP GLASS AND REUSE AS FEED STOCK 1
3.13 CAD/CAM 0
3.131 General 0
3.1311 OPTIMIZE DYE DESIGN 0
3.2 Equipment 467
3.21 General 467
3.211 Fault Tolerance 14
3.2111 INSTALL REDUNDANT EQUIPMENT TO AVOID LOSSES CAUSED BY EQUIPMENT FAILURE AND ROUTINE MAINTENANCE 14
3.212 Painting Operations 311
3.2121 CONVERT TO ELECTROSTATIC POWDER COATING 55
3.2122 CONVERT FROM WATER CURTAIN SPRAY BOOTHS TO A DRY SYSTEM 3
3.2123 CONVERT TO HIGH VOLUME LOW PRESSURE (HVLP) PAINT GUNS 238
3.2124 CONVERT TO AIR ASSISTED / AIRLESS PAINT GUNS 15
3.213 Process Specific Upgrades 7
3.2131 INSTALL MIXERS ON EACH CLEANING TANK 0
3.2132 INCREASE FREEBOARD SPACE / INSTALL CHILLERS ON VAPOR DEGREASERS 0
3.2133 ELIMINATE CHEM ETCHING & PLATING BY USING ALTERNATIVE PRINT TECHNOLOGIES(PRE SENSITIZED LITHO,PLASTIC OR PHOTO POLYMER, 0
3.2134 USE HIGH PURITY ANODES TO INCREASE SOLUTION LIFE 1
3.2135 EXTEND SOLUTION LIFE WITH FILTERING OR CARBONATE FREEZING 4
3.2136 USE "WASH-LESS" PROCESSING EQUIPMENT 2
3.2137 USE INDUCTION FURNACES INSTEAD OF ELECTRIC ARC OR CUPOLA FURNACES TO REDUCE DUST AND FUMES 0
3.214 Tank Design 3
3.2141 USE CYLINDRICAL TANKS WITH HEIGHT TO DIAMETER RATIOS CLOSE TO ONE TO REDUCE WETTED SURFACE 2
3.2142 USE TANKS WITH A CONICAL BOTTOM OUTLET SECTION TO REDUCE WASTE ASSOCIATED WITH THE INTERFACE OF TWO LIQUIDS 1
3.216 System Monitoring 4
3.2161 CLOSELY MONITOR CHEMICAL ADDITIONS TO INCREASE BATH LIFE 3
3.2162 INSTALL WEB BREAK DETECTORS TO PREVENT EXCESSIVE WASTE PAPER 1
3.2163 USE INK WATER RATIO SENSOR 0
3.217 Automation 128
3.2171 USE AN AUTOMATIC PLATE PROCESSOR 4
3.2172 USE AUTOMATIC CLEANING EQUIPMENT 12
3.2173 CONVERT TO ROBOTIC PAINTING 2
3.2174 AUTOMATE INK MIXING 2
3.2175 USE AUTOMATED PLATE BENDERS 0
3.2176 INCREASE USE OF AUTOMATION 108
3.3 Post Generation Treatment / Minimization 401
3.31 General 401
3.311 Neutralization 16
3.3111 ADJUST PH FOR NEUTRALIZATION 5
3.3112 UTILIZE OXIDATION/REDUCTION FOR NEUTRALIZATION 2
3.3113 USE OTHER METHODS FOR NEUTRALIZATION 9
3.312 Removal of Contaminants 202
3.3121 USE SCREENING, MAGNETIC SEPARATION TO REMOVE CONTAMINANTS 5
3.3122 USE FILTRATION, CENTRIFUGING TO REMOVE CONTAMINANTS 77
3.3123 USE DECANTING, FLOTATION TO REMOVE CONTAMINANTS 5
3.3124 USE CYCLONE SEPARATION TO REMOVE CONTAMINANTS 2
3.3125 USE DISTILLATION, EVAPORATION TO REMOVE CONTAMINANTS 37
3.3126 USE ABSORPTION, EXTRACTION TO REMOVE CONTAMINANTS 7
3.3127 USE ADSORPTION, ION EXCHANGE TO REMOVE CONTAMINANTS 10
3.3128 UTILIZE OTHER METHODS TO REMOVE CONTAMINANTS 59
3.313 Material Concentration 183
3.3131 USE EVAPORATION TO CONCENTRATE MATERIAL 139
3.3132 USE REVERSE OSMOSIS TO CONCENTRATE MATERIAL 19
3.3133 USE OTHER WASTE CONCENTRATION METHODS 25
3.4 Water Use 2,112
3.41 General 2,112
3.411 Close Cycle Water Use 1,071
3.4111 USE CLOSED CYCLE PROCESS TO MINIMIZE WASTE WATER PRODUCTION 280
3.4112 RECOVERY METALS FROM RINSE WATER(EVAP., ION EXCHANGE, RO, ELECTROLYSIS, ELECTRODIALYSIS) AND REUSE RINSE WATER 25
3.4113 TREAT AND REUSE RINSE WATERS 118
3.4114 REPLACE CITY WATER WITH RECYCLED WATER VIA COOLING TOWER 169
3.4115 RECOVER AND REUSE COOLING WATER 278
3.4116 METER RECYCLED WATER (TO REDUCE SEWER CHARGES) 201
3.413 Water Quality 26
3.4131 MINIMIZE CONTAMINATION OF WATER BEFORE TREATMENT 20
3.4132 USE DEIONIZED WATER IN UPSTREAM RINSE TANKS 2
3.4133 CLEAN FOULING FROM WATER LINES REGULARLY 4
3.414 Water Treatment 41
3.4141 REPLACE THE CHLORINATION STAGE WITH AN OXYGEN OR OZONE STAGE 16
3.4142 RECYCLE CHLORINATION STAGE PROCESS WATER 1
3.4143 USE WATER FROM THE WASHING SYSTEM IN THE CHLORINATION STAGE 2
3.4144 PERFORM HIGH CONSISTENCY GAS PHASE CHLORINATION 1
3.4145 USE MAGNETIC TECHNOLOGY TO TREAT WATER 20
3.4146 CHANGE METHOD OF DEIONIZED WATER PRODUCTION 1
3.415 Reduction 974
3.4151 MINIMIZE WATER USAGE 476
3.4152 CAREFULLY CONTROL WATER LEVEL IN MASS FINISHING EQUIPMENT 2
3.4153 USE COUNTER CURRENT RINSING TO REDUCE WASTE WATER 20
3.4154 ELIMINATE LEAKS IN WATER LINES AND VALVES 155
3.4155 METER WASTE WATER 198
3.4156 USE FLOW CONTROL VALVES ON EQUIPMENT TO OPTIMIZE WATER USE 91
3.4157 REPLACE WATER COOLING ON PROCESSES WITH AIR COOLING 23
3.4158 USE MINIMUM COOLING WATER TO BEARINGS 3
3.4159 REPLACE TREATED WATER WITH WELL / SURFACE WATER 6
3.5 Recycling 2,820
3.51 Liquid Waste 217
3.511 Oil 87
3.5111 FILTER AND REUSE HYDRAULIC OIL 35
3.5112 REPROCESS SPENT OILS ON SITE FOR RE-USE 40
3.5113 SELL OIL TO RECYCLER 12
3.512 Ink 30
3.5121 RECYCLE WASTE INK AND CLEANUP SOLVENT 30
3.513 White Water 29
3.5131 RECYCLE WHITE WATER 25
3.5132 REUSE RICH WHITE WATER IN OTHER APPLICATIONS 4
3.514 Miscellaneous 71
3.5141 RECOVER DYE FROM WASTE WATERS 0
3.5142 TREAT AND REUSE EQUIPMENT CLEANING SOLUTIONS 11
3.5143 RETURN SPENT SOLUTIONS TO THE MANUFACTURER 5
3.5144 RECYCLE SPENT TANNING SOLUTION 1
3.5145 RECOVER AND REUSE SPENT ACID BATHS 16
3.5146 UTILIZE A CENTRAL COOLANT SYSTEM FOR CLEANING AND REUSE OF METAL WORKING FLUID 38
3.52 Solid Waste 720
3.521 General 483
3.5211 REUSE SCRAP GLASS AS FEED STOCK 8
3.5212 REGRIND, REUSE, OR SELL SCRAP PLASTIC PARTS 189
3.5213 REUSE SCRAP PRINTED PAPER FOR MAKE-READY 4
3.5214 AVOID CONTAMINATION OF FLASHING / REJECT S AND USE AS FEED STOCK 0
3.5215 AVOID CONTAMINATION OF END PIECES AND REUSE AS FEED STOCK 6
3.5216 RECYCLE NONFERROUS DUST 9
3.5217 REUSE / RECYCLE/ SELL PAPER PRODUCTS 240
3.5218 REUSE / RECYCLE/ SELL RUBBER PRODUCTS 27
3.522 Sand 39
3.5221 RECYCLE CASTING SAND 28
3.5222 USE SAND FOR OTHER PURPOSES (EG CONSTRUCTION FILL, COVER FOR MUNICIPAL LANDFILLS) 11
3.524 Metals 198
3.5241 SELL USED PLATES TO AN ALUMINUM RECYCLER 8
3.5242 RECOVER METALS FROM SPENT SOLUTIONS AND RECYCLE 20
3.5243 RECYCLE FILM FOR SILVER RECOVERY 3
3.5244 RECOVER METALS FROM CASTING SAND 3
3.5245 SEPARATE AND RECYCLE SCRAP METAL TO FOUNDRY 42
3.5246 SEGREGATE METALS FOR SALE TO A RECYCLER 122
3.5247 SEPARATE IRON FROM SLAG AND REMELT 0
3.53 Other Materials 1,883
3.531 General 1,883
3.5311 RECOVER AND REUSE WASTE MATERIAL 266
3.5312 SALVAGE AND RE-USE PROCESS WASTE 51
3.5313 INCREASE AMOUNT OF WASTE RECOVERED FOR RESALE 316
3.5314 USE IN-PROCESS RECYCLING WHENEVER POSSIBLE 45
3.5315 LEASE / PURCHASE BALER; SELL CARDBOARD TO RECYCLER 707
3.5316 CONTRACT A WOOD PALLET RECYCLING COMPANY 449
3.5317 SELL / OFFER BY-PRODUCT AS ANIMAL FEED 27
3.5318 RECYCLE FLUORESCENT LAMPS 22
3.6 Waste Disposal 1,345
3.61 General 1,345
3.611 Sludge Maintenance 82
3.6111 USE ALTERNATIVE FLOCCULENT TO MINIMIZE SLUDGE VOLUME 7
3.6112 USE FILTER AND DRYING OVEN TO REDUCE SLUDGE VOLUME 62
3.6113 REMOVE SLUDGE FROM TANKS ON A REGULAR BASIS 6
3.6114 USE PRECIPITATING AGENTS IN WASTE WATER TREATMENT THAT PRODUCE THE LEAST QUANTITY OF WASTE 7
3.612 Combustion of Waste Products 233
3.6121 BURN WASTE PAPER FOR HEAT 12
3.6122 INSTALL SOLID WASTE INCINERATOR FOR HEAT 19
3.6123 BURN WOOD BY-PRODUCTS FOR HEAT 55
3.6124 BURN WASTE OIL FOR HEAT 119
3.6125 SELL COMBUSTIBLE WASTE 22
3.6126 DIRECT WASTE GASSES TO BOILER COMBUSTION AIR 6
3.619 Miscellaneous 1,030
3.6191 RETURN SPENT SOLUTIONS TO THE MANUFACTURER 1
3.6192 USE A LESS EXPENSIVE METHOD OF WASTE REMOVAL 383
3.6193 INSTALL EQUIPMENT (eg COMPACTOR) TO REDUCE DISPOSAL COSTS 636
3.6194 SHIP HYDRAULIC OIL TO SECONDARY FUEL PROGRAM 10
3.7 Maintenance 527
3.71 Cleaning / Degreasing 346
3.711 Mechanical Cleaning 7
3.7111 USE VACUUM FOR SPILL CLEANUP INSTEAD OF ABSORBENT 0
3.7112 USE SQUEEGEES, MOPS, AND VACUUMS FOR FLOOR CLEANING 3
3.7113 USE MECHANICAL WIPERS FOR CLEANING OF VESSELS 1
3.7114 USE SQUEEGEES TO RECOVER CLINGING PRODUCT PRIOR TO RINSING 0
3.7115 CLEAN LINES WITH "PIGS" INSTEAD OF SOLVENTS / SOLUTIONS 3
3.712 Reduction of Cleaning 26
3.7121 IMPROVE HANDLING PRACTICES 18
3.7122 MAXIMIZE PRODUCTION RUNS TO REDUCE CLEANING 3
3.7123 USE CONTINUOUS PROCESSING 1
3.7124 INSTALL DEDICATED MIXING EQUIP TO OPTIMIZE REUSE OF USED RINSEATE & TO PRECLUDE THE NEED FOR INTER-RUN CLEANING 2
3.7125 SHORTEN PAINT LINES AS MUCH AS POSSIBLE 1
3.7126 USE PEEL COATINGS ON RAW MATERIALS 0
3.7127 MINIMIZE PART CONTAMINATION BEFORE WASHING 1
3.713 Rag Use 156
3.7131 USE A RAG RECYCLE SERVICE 47
3.7132 REUSE RAGS UNTIL COMPLETELY SOILED 33
3.7133 USE RAGS SIZED FOR EACH JOB 2
3.7134 WASH AND REUSE RAGS ON-SITE 20
3.7135 MINIMIZE USE OF RAGS THROUGH WORKER TRAINING 5
3.7136 MARKET WASTE MATERIALS AS CLEAN-UP RAGS 0
3.7137 REPLACE CLOTH RAGS WITH PAPER TOWELS 49
3.714 Preventive Maintenance 12
3.7141 IMPROVE CLEANING EFFICIENCY BY MAINTAINING CLEANING SYSTEM 10
3.7142 USE CLEAN IN PLACE (CIP) SYSTEMS 2
3.7143 CLEAN EQUIPMENT IMMEDIATELY AFTER USE 0
3.719 Miscellaneous 145
3.7191 USE WATER BASED SPRAY ABRASIVES INSTEAD OF BAR ABRASIVES 2
3.7192 USE DRY CLEANING METHODS WHENEVER POSSIBLE 0
3.7193 USE HIGH PRESSURE WASH SYSTEMS 3
3.7194 USE DISPOSABLE LINERS IN TANKS 0
3.7195 USE TEFLON LINED TANKS 2
3.7196 USE RE-USABLE FILTERS 37
3.7197 USE ULTRASONIC CLEANING 8
3.7198 REDUCE / ELIMINATE USE OF DISPOSABLE PRODUCT 93
3.72 Spillage 109
3.721 Operations 88
3.7211 MODIFY MATERIAL APPLICATION METHODS 16
3.7212 IMPROVED MATERIAL HANDLING (MIXING AND TRANSFER) 27
3.7213 USE MORE EFFICIENT SPRAY METHOD FOR GELCOAT APPLICATION 2
3.7214 REDUCE OR ELIMINATE WASTE 43
3.7215 AVOID INSERTING OVERSIZED OBJECT TO REDUCE PISTON EFFECT 0
3.722 Hardware 21
3.7221 IMPROVE PROCESS CONTROL TO PREVENT SPILLS OF MATERIAL 12
3.7222 MINIMIZE OVERFLOWS BY INSTALLING LEVEL CONTROLS 2
3.7223 INSTALL SHROUDING ON MACHINES TO PREVENT SPLASHING 5
3.7224 USE PUMPS AND PIPING TO DECREASE THE FREQUENCY OF SPILLAGE DURING MATERIAL TRANSFER 2
3.73 Other 72
3.731 Leak Reduction 60
3.7311 MAINTAIN MACHINES TO REDUCE LEAKS 38
3.7312 IMPLEMENT A REGULAR MAINTENANCE PROGRAM TO REDUCE EMISSIONS FROM LEAKY VALVES AND PIPE FITTINGS 20
3.7313 ELIMINATE OXYGEN LOSS 2
3.739 Miscellaneous 12
3.7391 IMPLEMENT A MAINTENANCE PROGRAM TO KEEP RACKS AND TANKS FREE OF RUST, CRACKS, OR CORROSION 2
3.7392 APPLY A PROTECTIVE COATING TO RACKS AND TANKS 5
3.7393 IMPLEMENT A MACHINE AND COOLANT SUMP CLEANING PROGRAM TO MINIMIZE COOLANT CONTAMINATION 5
3.8 Raw Materials 475
3.81 Solvents 386
3.811 Use Reduction 9
3.8111 MAINTAIN WATER SEPARATOR AND COMPLETELY DRY PARTS TO AVOID WATER CONTAMINATION OF SOLVENT 1
3.8112 USE DEIONIZED WATER FOR MAKE-UP AND RINSE WATER TO INCREASE SOLUTION LIFE 1
3.8113 PREVENT EXCESSIVE SOLVENT USAGE (OPERATOR TRAINING) 6
3.8114 AUTOMATE PAINT MIXING-USE COMPRESSED AIR BLOWOUT FOR LINE CLEANING PRIOR TO SOLVENT CLEANING 0
3.8115 REDUCE THE NUMBER OF PARTS WASHERS 1
3.812 Emission Reduction 52
3.8121 COVER CONTAINERS TO MINIMIZE EVAPORATIVE LOSSES 24
3.8122 USE TIGHT-FITTING LIDS ON MATERIAL CONTAINERS TO REDUCE VOC EMISSIONS 6
3.8124 INSTALL FLOATING COVERS ON TANKS OF VOLATILE MATERIALS TO REDUCE EVAPORATION 4
3.8125 REMOVE ROLLERS FROM THE MACHINES AND CLEAN IN A CLOSED SOLVENT CLEANER 17
3.8126 USE FLUE GAS RECUPERATION TO REDUCE VOC 1
3.813 Material Replacement 164
3.8131 USE WATER-BASED ADHESIVES 8
3.8132 USE LESS TOXIC AND VOLATILE SOLVENT SUBSTITUTES 114
3.8133 CONVERT TO AQUEOUS CLEANING 17
3.8134 USE WATER-BASED CUTTING FLUIDS TO ELIMINATE NEED FOR SOLVENT CLEANING 3
3.8135 USE LOW VOC OR WATER BASED PAINT 4
3.8136 SWITCH TO A SOLVENT THAT CAN BE CLEANED AND RE-USED 15
3.8137 USE SOY OR WATER-BASED INKS 3
3.814 Solvent Recovery 161
3.8141 REGENERATE CLEANING SOLVENT ON-SITE AND REUSE 12
3.8142 DISTILL CONTAMINATED SOLVENTS FOR REUSE 110
3.8143 RECYCLE CLEANING SOLVENT AND REUSE 39
3.82 Other Solutions 59
3.821 Water-Based Substitutes 35
3.8211 CONVERT TO AQUEOUS CLEANING SYSTEM 33
3.8212 USE WATER-BASED IMAGE PROCESSING CHEMICALS 0
3.8213 USE WATER BASED OR GREASELESS BINDERS TO INCREASE WHEEL LIFE 0
3.8214 USE WATER-BASED DEVELOPERS AND FINISHERS 2
3.822 Other Substitutes 24
3.8221 USE ALTERNATIVES FOR ACIDS / ALKALINE (WATER, STEAM, ABRASIVE) 7
3.8222 USE REACTIVE RINSING TO EXTEND BATH LIFE 0
3.8223 USE NON-PHENOLIC STRIPPERS TO REDUCE TOXICITY ASSOCIATED WITH PHENOL AND ACID ADDITIVES 0
3.8224 CONVERT TO LESS TOXIC HYDROCARBON CLEANERS 14
3.8225 REPLACE HEXAVALENT CHROMIUM SOLUTIONS WITH TRIVALENT SOLUTIONS 2
3.8226 USE CYANIDE FREE SOLUTIONS WHENEVER POSSIBLE 0
3.8227 REPLACE CADMIUM-BASED SOLUTIONS WITH ZINC SOLUTIONS 0
3.8228 REPLACE HEAVY METAL REAGENTS WITH NON-HAZARDOUS REAGENTS 1
3.83 Solids 30
3.831 General 30
3.8311 USE SILVER FREE FILMS 0
3.8312 USE BUILDING MATERIALS WHICH REQUIRE LESS ENERGY TO PRODUCE 3
3.8313 ALTER RAW MATERIALS TO REDUCE AIR EMISSIONS 3
3.8314 PURCHASE HIGH MATERIALS IN RETURNABLE BULK CONTAINERS 24
4. DIRECT PRODUCTIVITY ENHANCEMENTS 5,648
4.1 MANUFACTURING ENHANCEMENTS 1,128
4.11 Bottleneck Reduction 661
4.111 ADD EQUIPMENT/ OPERATORS TO REDUCE PRODUCTION BOTTLENECK 490
4.112 REPLACE OLD MACHINE WITH NEW AUTOMATIC MULTI-STATION TOOL 91
4.113 INSTALL REFRIGERATION SYSTEM TO COOL PRODUCT 23
4.114 ADD/MODIFY EQUIPMENT TO IMPROVE DRYING PROCESS 57
4.12 Defect Reduction 269
4.121 MAINTAIN CLEAN CONDITIONS BEFORE PAINTING 13
4.122 DEVELOP STANDARD PROCEDURES TO IMPROVE INTERNAL YIELDS 141
4.123 REDUCE DEFECTS BY REDUCING PRODUCT TIPPING 21
4.124 INSTALL CONTINUOUS LUBRICATION EQUIPMENT 6
4.125 MODIFY PROCESS TO REDUCE MATERIAL COSTS 42
4.126 INSTALL SENSORS TO DETECT DEFECTS 46
4.13 Material Reduction 198
4.131 MODIFY PROCESS TO REDUCE MATERIAL USE/COST 146
4.132 PURCHASE NEW EQUIPMENT TO REDUCE MATERIAL USE / COST 52
4.2 Purchasing 314
4.21 Raw Materials 212
4.211 CONSIDER USE / PURCHASE OF BULK MATERIALS WHERE POSSIBLE 112
4.212 ADOPT IN-HOUSE MATERIAL GENERATION 67
4.213 PURCHASE MATERIAL FROM SUPPLIER IN CUSTOMIZED PACKAGING 18
4.214 PURCHASE APPROPRIATELY SIZED MATERIAL 15
4.22 Ancillary Materials 28
4.221 USE ONLY AMOUNT OF PACKAGING MATERIAL NECESSARY 11
4.222 PURCHASE RE-CONDITIONED MATERIAL INSTEAD OF NEW 17
4.23 Capital 74
4.231 PURCHASE EQUIPMENT INSTEAD OF LEASING 65
4.232 LEASE EQUIPMENT INSTEAD OF PURCHASING 9
4.3 Inventory 299
4.31 Just in Time 33
4.311 SCHEDULE DELIVERIES ACCORDING TO DEMAND 33
4.32 Other Inventory Controls 266
4.321 OPTIMIZE PRODUCTION LOT SIZES AND INVENTORIES 111
4.322 ELIMINATE OLD STOCK AND MODIFY INVENTORY CONTROL 127
4.323 OPTIMIZE LOT SIZES TO REDUCE INVENTORY CARRYING COSTS 28
4.4 Labor Optimization 1,687
4.42 Practices/Procedures 498
4.421 MODIFY CURRENT INCENTIVE PROGRAM 75
4.422 UTILIZE OUTSIDE CONTRACTING 20
4.423 MOVE PRODUCT USING MECHANICAL MEANS 159
4.424 IMPROVE SPACE COMFORT CONDITIONING 127
4.425 ELIMINATE/REDUCE REDUNDANT INSPECTIONS 50
4.426 MODIFY WORKLOAD 67
4.43 Training 255
4.431 TRAIN OPERATORS FOR MAXIMUM OPERATING EFFICIENCY 192
4.432 CROSS-TRAIN PERSONNEL TO AVOID LOST TIME 63
4.44 Automation 780
4.441 INSTALL AUTOMATIC PACKING EQUIPMENT 299
4.442 INSTALL MAGAZINES FOR TEMPORARY STORAGE 11
4.443 INSTALL AUTOMATIC BOILER FUEL FEED SYSTEM 5
4.444 INSTALL SYSTEM TO COLLECT SCRAP 46
4.445 INSTALL EQUIPMENT TO MOVE PRODUCT 216
4.446 AUTOMATE FINISHING PROCESS 115
4.447 AUTOMATE PAYROLL SYSTEM 64
4.448 INSTALL AUTOMATIC PART STORAGE / RETREVAL SYSTEM 24
4.45 Scheduling 154
4.451 ADD ADDITIONAL PRODUCTION SHIFT 45
4.452 ELIMINATE SHIFT 39
4.453 RESCHEDULE BREAKS TO ALLOW FOR CONTINUOUS PRODUCTION 14
4.454 MODIFY STARTUP/SHUTDOWN TIMES 56
4.46 MAINTENANCE 0
4.461 REMOVE HOT SLAG BEFORE IT HARDENS 0
4.463 MODIFY FACILITY TO AVOID EXCESS MAINTENANCE COSTS 0
4.5 Space Utilization 639
4.51 Floor Layout 482
4.511 EXPAND OPERATIONS INTO UNUSED SPACE 47
4.512 CONDENSE OPERATION INTO ONE BUILDING 40
4.513 RE-ARRANGE EQUIPMENT LAYOUT TO REDUCE LABOR COSTS 189
4.514 RE-ARRANGE EQUIPMENT LAYOUT TO REDUCE HANDLING COSTS 152
4.515 INSTALL SHELVES / RACKS TO UTILIZE UNUSED SPACE 54
4.52 Rental Space 157
4.521 CLEAR AND RENT EXISTING SPACE 113
4.522 MODIFY STORAGE SPACE TO AVOID RENTAL OF A WAREHOUSE 44
4.6 Reduction of Downtime 1,089
4.61 Maintenance 359
4.611 BEGIN A PRACTICE OF PREDICTIVE / PREVENTATIVE MAINTENANCE 356
4.612 CONTRACT OUT MAINTENANCE 3
4.62 Quick Change 165
4.621 USE FIXTURES TO REDUCE MACHINE CHANGEOUT TIMES 56
4.622 INSTALL ROTATING CAROUSELS TO REDUCE SET-UP TIMES 3
4.623 EMPLOY MODULAR JIGS TO REDUCE PROCESS SET-UP TIME 17
4.624 HIRE ADDITIONAL PERSONNEL TO REDUCE CHANGEOUT TIME 18
4.625 DEVELOP STANDARD OPERATING PROCEDURES 71
4.63 Power Conditioning 73
4.631 INSTALL AN UNINTERUPTABLE POWER SUPPLY 32
4.632 CHANGE OPERATING CONDITIONS 41
4.64 Alarms 19
4.641 ELIMINATE SHUTDOWNS OF CONTROLS DUE TO OVERHEATING 4
4.642 INSTALL SENSORS TO DETECT AND AVOID JAMS 15
4.65 Other Equipment 473
4.651 INSTALL BACK-UP EQUIPMENT 52
4.652 REPLACE EXISTING EQUIPMENT WITH MORE SUITABLE SUBSTITUTES 412
4.653 MAINTAIN/ENLARGE A STOCK OF SPARE PARTS 9
4.7 Management Practices 106
4.71 Total Quality Management 82
4.711 INITIATE A TOTAL QUALITY MANAGEMENT PROGRAM 79
4.712 UTILIZE JOB COSTING SOFTWARE 3
4.72 Certifications 11
4.721 INITIATE A PROGRAM TO ACQUIRE ISO CERTIFICATION 11
4.73 Marketing 13
4.731 ADVERTISE PRODUCT OR SERVICE 13
4.8 Other Administrative Savings 386
4.81 Taxes 75
4.811 DEMOLISH OLD BUILDING TO REDUCE TAX AND INSURANCE BILLS 29
4.812 APPLY FOR INVESTMENT INCENTIVES 46
4.82 Fees 311
4.821 PAY BILLS ON TIME TO AVOID LATE FEES 311