Plant-wide energy assessments identify overall energy use in manufacturing processes— 

which can account for 10 percent or more of an industry’s total operating costs—and 

highlight opportunities for best energy management practices for industry, including 

the adoption of new, efficient technologies. The Office of Energy Efficiency and 

Renewable Energy’s Industrial Technologies Program works with companies to 

characterize findings and document savings that can be replicated in other facilities 

and other industries for multiplied savings. On average, the findings from a single 

assessment can be replicated in at least seven other facilities with equivalent 

systems and energy use. For a relatively low initial investment, companies that 

participate in assessments can expect to realize a minimum of $1 million in savings 

annually from energy costs, waste reduction, and increased productivity—usually 

with a payback of less than 18 months. 

Solicitations Encourage Companies to Participate 

Interested companies are invited to submit proposals in response to a plant-wide 

assessment solicitation usually offered once a year. Specifically, proposals are sought 

where industry-defined teams will be considering the adoption of best available and 

emerging technology using state-of-the-art tools, information, process engineering 

techniques, and best practices for operating and planned plant support and process 

systems. Industrial sites that fall within the Industrial Technologies Program’s 

tives are considered for an award. These include industries such as, but not limited 

to, forest products, chemicals, petroleum, steel, aluminum, metal casting, glass, mining, and agriculture industries. Funding of up to $100,000 is available for each project 

selected, with a required industrial cost share of at least 50 percent. Companies are 

strongly encouraged to develop and work closely with teams which could be composed of their resource and equipment suppliers, engineering firms, and other third 

party entities. Solicitation information is posted to the Industrial Technologies Program 

and BestPractices Web sites (www.oit.doe.gov/bestpractices), and is sometimes 

advertised in industry trade magazines. 

Plant assessments address a variety of generic and industry-specific technology 

areas, and a variety of plant/process optimization methods. Proposal writers should 

also consider demand-side energy management best practices and technology 

implementation in plant steam delivery and process heating systems; electric-motor 

systems (including motors, drives, pumps, fans, blowers); compressed air systems; 

and heat exchange optimization (e.g., pinch technology). In addition, proposal writers 

should consider supply-side options using cogeneration and combined heat and 

power system technologies. 

PLANT-WIDE ASSESSMENTS HELP INDUSTRY IDENTIFY 

ENERGY AND COST SAVINGS OPPORTUNITIES 

April 2003 

OFFICE OF INDUSTRIAL TECHNOLOGIES 

ENERGY EFFICIENCY AND RENEWABLE ENERGY, U.S. DEPARTMENT OF ENERGY 

INDUSTRIES OF THE FUTURE 

BestPractices 

BENEFITS 

• Identify areas for cost and energy 

savings, for emissions and waste 

reduction, and for productivity 

improvements 

• Receive expert technical assistance 

• Access software tools to assist in 

decision making 

• Share costs of assessment and 

leverage resources 

Visit www.oit.doe.gov/bestpractices 

to read plant assessment case 

studies. 

Plant-Wide 

Assessments 

Plant-Wide 

Assessments 

initia­
The results, successes, and experiences from these assessments are published 

in case studies (which are also posted to the BestPractices Web site) and the 

Energy Matters newsletter. Confidentiality is protected and no proprietary company 

information is released. By publicizing assessment findings and results, the 

Industrial Technologies Program encourages other U.S. manufacturers to adopt 

and implement similar approaches for increasing energy efficiency and reducing 

environmental emissions. Participating plants will become aware of and gain 

access to all Industrial Technologies Program emerging technologies and best 

practices, and tools and information resources that could help them implement the 

most cost-effective, state-of-the-art technology. 

Additional Assessment Options 

Small- to medium-sized manufacturers may be eligible to receive assessments by 

university-based Industrial Assessment Centers. Teams of engineering faculty 

and students from the centers—located at 26 universities around the country— 

conduct energy, waste reduction, and productivity-improvement audits and then 

provide recommendations to manufacturers. Recommendations from industrial 

assessments have averaged about $55,000 in potential annual savings for 

each manufacturer. For more information, visit the Industrial Assessment Center 

Web site at www.oit.doe.gov/iac. 

BestPractices is part of the Industrial 

Technologies Program’s Industries 

of the Future strategy, which helps 

the country’s most energy-intensive 

industries improve their competitiveness. 

BestPractices brings together the bestavailable and emerging technologies 

and practices to help companies begin 

improving energy efficiency, environmental 

performance, and productivity right now. 

BestPractices focuses on plant systems, 

where significant efficiency improvements 

and savings can be achieved. Industry 

gains easy access to near-term and 

long-term solutions for improving the 

performance of motor, steam, compressed 

air, and process heating systems. In 

addition, the Industrial Assessment Centers 

provide comprehensive industrial energy 

evaluations to small and medium-size 

manufacturers. 

FOR ADDITIONAL INFORMATION, 

PLEASE CONTACT: 

Grace Ordaz


Industrial Technologies Program


Phone: (202) 586-8350


Fax: (202) 586-9234


www.oit.doe.gov/bestpractices


Industrial Technologies Clearinghouse


Phone: (800) 862-2086


Fax: (360) 586-8303


Clearinghouse@ee.doe.gov


Please send any comments, 


questions, or suggestions to 


webmaster.oit@ee.doe.gov


Visit our home page at


www.oit.doe.gov


Industrial Technologies Program


Energy Efficiency and Renewable


Energy, EE-2F


U.S. Department of Energy


Washington, DC 20585-0121


April 2003