Energy Matters

U.S. Department of Energy, Industrial Technologies Program

In This Issue

Features

3M Company Hosts 

Save Energy Now LEADER 

Showcase 1

Compressed Air Challenge 3

Success in Industry 

Three-Tiered Energy Audit 4

Brown Printing Company 5

New Belgium Brewing Company 6

DOE Grant Funds R&D Project 7

States & Utilities Corner

Sherwin-Williams Partners with 

Kentucky’s Save Energy Now 8

Tools of the Trade

The Energy Management Toolkit 9 

Research & Development

Aerogel: Material of the Future 10

Implementation

Sherwin-Williams and Alcoa

Discuss Strategies 11

ITP Case Studies Highlight 

Industrial Efficiency 12

IMPACTS 13

Ask the Energy Expert

UTC’s Five-Pronged Approach 14

International 16

Funding Resources 16

Training Opportunities 17

Look for Us... 18

Program Contacts 19

Winter 2011, Vol. 2, Iss. 2

Features

3M Company Hosts Save Energy 

Now LEADER Showcase, Promotes 

Launch of Save Energy Now

Corporate-Wide

On October 21–22, 2010, the 3M Company—in partnership with the U.S. Department of Energy’s Industrial Technologies Program (ITP)—hosted the 

Save Energy Now LEADER Showcase, “Launching and Implementing Save Energy 

Now Corporate-Wide,” at the company’s world headquarters in St. Paul, Minnesota. 

The goal of the Showcase was to demonstrate how industrial companies can increase 

their competitiveness by implementing energy efficiency and/or process improvements 

identified through participation in the LEADER initiative. 

More than 100 representatives from U.S. industrial companies, utilities, federal and state 

government agencies, energy service companies, and academia gathered to learn about 

the various crosscutting energy efficiency technologies 3M has implemented across its 

global operations—technologies that event participants may be able to implement in 

their own facilities to realize similar energy and cost savings. Participants also heard 

presentations from 3M representatives that ranged from overviews of the company’s 

corporate energy policy to specific measures implemented in individual facilities. 

For instance, 3M Corporate Energy Manager Steve Schultz provided information on 

how to implement key energy efficiency projects, how to replicate those projects in 

various locations, and how to provide motivation and recognition for employee efforts. 

Additionally, Energy Champions from several 3M plants (Hutchinson, Minnesota; 

Knoxville, Iowa; and Cottage Grove, Minnesota) highlighted energy efficiency activities 

implemented in their facilities.

Further, representatives from 3M and fellow LEADER Companies Alcoa, Briggs & 

Stratton, General Motors, Sherwin-Williams, and JR Simplot participated in a panel 

discussion to share Save Energy Now best practices. Panel members also provided 

advice to potential LEADER Companies in attendance about launching Save Energy 

Now corporate-wide, addressing how energy champions at their companies were able to 

make the business case for joining the program to senior management.
ENERGY MATTERS / WINTER 2011

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Attendees commended the energy efficiency examples provided 

during the Showcase; most were particularly impressed with the 

way the information was presented. “Reading case studies and 

fact sheets is one thing—they give good information and you can 

get a lot out of them, but you don’t get the ‘human element’ from 

that information,” said one attendee. “Sitting here and listening 

to someone talk about how energy efficiency has provided return 

on investment—hearing their passion about the subject and 

their enthusiasm about the subject matter—really motivates you 

to take what you’ve learned and put it into action in your own 

plant.”

While attendees praised the information provided by speakers 

and panel members, many found that the informal breakout 

sessions—including a networking breakfast and lunch, as well 

as discussions during breaks—also provided useful information. 

During these sessions, participants were able to talk with people 

from other companies about different—and, in some cases, 

revolutionary—industrial energy efficiency strategies. These 

peer-to-peer sessions allowed attendees to brainstorm with other 

like-minded people, and that brainstorming may have provided 

some of the most useful information of the event. 

Showcase participants were also given the chance to see energy 

efficiency measures in action. Attendees toured 3M’s Innovation 

Center, visited the campus’s utility plant, and attended an 

“Energy Fair” that provided information on ways to reduce 

energy consumption in homes and businesses.

Finally, with several representatives from the Minnesota State 

Energy Office and regional utilities on hand, the dialogue 

between presenters and attendees was able to produce meaningful 

opportunities for industrial companies. One representative 

from the State Energy Office said that the presentations and 

conversations allowed him to learn what energy efficiency 

measures plants were interested in implementing, and he could 

then use that information to work with the State Energy Office 

and utilities to provide rebates for those specific types of projects. 

Altogether, the 3M Showcase was a huge success—it provided 

a forum for the industrial community to share best practices, 

afforded the opportunity for networking and peer-to-peer 

interaction, and opened the door for new opportunities and 

partnerships. Recognizing the value of ITP’s Save Energy Now

program and its LEADER Showcases, U.S. Congresswoman 

Betty McCollum (D-Minnesota), who provided opening remarks 

at the event, stated, “In the U.S. industrial sector alone, energy 

efficiency measures have the potential to reduce the growth of 

U.S. energy demand by more than 20% in the next decade ... 

The Save Energy Now program offers a model public-private 

partnership to ensure we can and will meet that potential.”

More information and event presentations can be found on the 

Showcase’s website at http://3mdoeshowcase.govtools.us/. 

3M Results to Date

3M set a corporate goal to improve global 

energy efficiency 20% by 2010, with 2005 as 

the base year.

Identified nearly 2,000 projects, of which 1,100 

were implemented, providing $68 million in first 

year savings

Cut worldwide energy use indexed to net sales 

25% between 2005 and 2010

Energy teams at 3M facilities are working to 

achieve a further reduction of 15% by 2015.
ENERGY MATTERS / WINTER 2011

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For the typical industrial manufacturer, compressed air is one of the most important utility requirements, but is commonly 

the most misunderstood energy system. Optimization of 

compressed air systems is key to greater productivity, efficiency, 

and profitability. The Compressed Air Challenge® (CAC), in 

partnership with the U.S. Department of Energy (DOE) Industrial 

Technologies Program, has developed a rich portfolio of useful 

compressed air-related information resources, tools, and training 

seminars—all available with a few clicks of your mouse.

About Compressed Air Challenge

CAC is a voluntary collaboration of industrial users—

manufacturers, distributors, and their associations; consultants; 

state research and development agencies; energy efficiency 

organizations; and utilities. These stakeholders work together 

to execute CAC’s mission: to provide resources that educate 

industry about optimizing compressed air systems, thereby 

increasing net profits. CAC has trained more than 12,000 

compressed air users since 1999. 

CAC has one purpose in mind—helping you improve the 

performance of your compressed air system. In the United 

States, compressed air systems account for $1.5 billion per 

year in energy costs. Optimization of compressed air systems 

can provide typical energy efficiency improvements averaging 

between 20% and 50%, pushing as high as 80% in some cases. 

Additional Benefits

In today’s industrial settings, approximately 90% of companies 

use compressed air in some part of their operations. Of this 

percentage of users, approximately two-thirds have some type 

of problem with their systems—obvious or not. Some of these 

problems result from installing the wrong type of compressor, 

improper cleanup equipment, inappropriate control methods, or 

unsound installation practices. The bottom line: these problems 

are very costly in the long run. These hidden costs can be seen 

Compressed Air Challenge: Training and 

Resources Designed with You in Mind 

in reduced equipment life and advanced operating costs. These 

are all symptoms of a much larger problem—a general lack of 

understanding of compressed air systems. However, there is no 

such thing as a foolproof compressed air system—even the best 

systems have the potential for serious problems.

Training: Solve Problems and Save Energy

To help users understand their system problems and what to 

do about them, CAC has developed two levels of training for 

plant engineers: Fundamentals of Compressed Air Systems 

and Advanced Management of Compressed Air Systems. 

Last year, CAC launched Fundamentals of Compressed Air 

Systems WE (Web-edition). This Web-based version of the 

popular Fundamentals of Compressed Air Systems training 

uses an interactive format that enables the instructor to diagram 

examples, give pop quizzes, and answer students’ questions in 

real time, and is delivered on a platform that eliminates travel 

costs for attendees. To date, CAC has held four highly rated 

sessions with four more scheduled in 2011. CAC’s Training 

Calendar and ITP’s BestPractices Training Calendar provide 

online registration links for all WE sessions, as well as other inperson sessions across the country. 

Hosting Opportunities

Many organizations have found hosting CAC seminars as an 

excellent way to enhance local knowledge of compressed air 

system best practices, providing a catalyst for positive change. 

CAC seminars are designed to be self-supporting. However, pretrained seminar leaders and course workbooks are made available 

simply by contacting info@compressedairchallenge.org. All you 

need to provide is the meeting space, audio visual equipment, and 

attendees. Whether you are employed by an energy organization 

or a local manufacturer, CAC is available to assist you in setting 

up your seminar by providing you with a hosting kit. DOE 

funding is available for qualified organizations to help mitigate 

the costs of trainers and workbook materials.
ENERGY MATTERS / WINTER 2011

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“We’ve developed a philosophy in our company 

around energy efficiency, comfort, and safety 

that we implement internally and bring to our 

customers worldwide.”

- Steve Rennie,

Ingersoll Rand Vice President of Integration

Compressed Air System Best Practices Manual

In 2009, CAC released Best Practices for Compressed Air 

Systems Second Edition, an updated edition of the highly 

successful 2003 manual. The Best Practices Manual was 

developed to provide readers with the tools necessary to reduce 

operating costs associated with the use of compressed air 

and to improve the reliability of the entire system. This onesource manual addresses all of the improvement opportunities 

associated with compressed air systems—from end-uses to the 

air entering the compressor inlet filter. The Best Practices Manual 

provides how-to information that will help users implement 

recommendations that achieve peak performance and system 

reliability at the lowest operating cost. The Best Practices 

Manual is a free benefit of attending our Fundamentals seminars. 

Additional copies are available for purchase at the 

CAC Bookstore. 

Free Informational Resources

In addition to the Best Practices Manual, CAC offers a 

comprehensive set of informational resource materials, such 

as Guidelines for Selecting a Compressed Air System Service 

Provider and Improving Compressed Air System Performance:

A Sourcebook for Industry. 

Other links to compressed air tools include

• AIRMaster +: A DOE software tool designed to help 

you maximize the efficiency and performance of your 

compressed air system through improved operations and 

maintenance practices

• Log-Tool: An import tool that significantly enhances the 

usability of AIRMaster+.

Additionally, CAC’s Online Library is home to a wealth of other 

resources, including fact sheets, tip sheets, case studies, and 

articles on a variety of compressed air-related topics.

Sponsorship Opportunities

CAC sponsorship has always been open to interested, qualifying 

organizations (subject to approval by the CAC Board). However, 

starting in 2011, there is an additional option for energy-related 

magazines, online magazines, associations, public entities, 

energy efficiency program administrators, and utilities to become 

“affiliate” members. Affiliate members will receive the following 

benefits: discounts on training, a newsletter, and a listing on 

CAC’s website. Affiliates are also permitted to display the CAC 

affiliate logo on their websites. 

If you are interested in learning more about becoming a sponsor 

or affiliate, or would like to speak to someone about CAC 

training opportunities and educational resources, please e-mail 

info@compressedairchallenge.org.

Success in Industry

Three-Tiered Energy Audit Program Saves 

Company $4 Million in Energy Costs

At Ingersoll Rand, the drive to provide safe, comfortable, and efficient products and services does not end with 

customers—those same standards are being upheld throughout 

the company’s operations. In 2009, Ingersoll Rand made 

improving the energy efficiency of its global operations a top 

priority when it joined the U.S. Department of Energy Industrial 

Technologies Program Save Energy Now LEADER initiative. 

This commitment is a cornerstone of Ingersoll Rand’s efforts to 

reduce its global energy intensity 25% by 2019. At the center of 

the company’s energy strategy lays a three-tiered energy audit 
ENERGY MATTERS / WINTER 2011

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Brown Printing Company: 

Using Its Environment to Save Energy

program that helps reduce energy use and operating costs at 

many of its largest manufacturing facilities. The program relies 

heavily on employee volunteers with energy and engineering 

expertise to join an Expanded Energy Audit team two to three 

times a year. These teams participate in assessments that not only 

provide the chance to identify opportunities for improvement, but 

also educate plant staff about the American National Standards 

Institute (ANSI) Management System for Energy (MSE) 

2000:2008 standard and new energy efficient technologies.

Ingersoll Rand’s three-tiered energy audit program consists of the 

following three elements: 

•	 Level 1: Treasure Hunt – Level 1 audits focus on the 

evaluation of low-cost measures, energy management 

behavior, and easy-to-implement projects.

•	 Level 2: Expanded Energy Audit – Level 2 audits 

include three-day visits at high-priority sites and focus on 

energy using equipment and processes.

•	 Level 3: System-Specific Audit – Level 3 audits focus on 

compressed air or heating, ventilating, and air conditioning 

systems.

Through this approach to energy management, Ingersoll Rand 

has conducted a number of Level 1, 2, and 3 audits at several of 

its facilities, and the company has implemented many projects 

that have generated substantial energy savings. Altogether, the 

company has saved more than $4 million in energy costs globally 

since the inception of its auditing efforts in 2005.

A combination of strong corporate leadership, cross-facility 

collaboration, and a dedicated staff willing to work off an initial 

concept has led Ingersoll Rand to achieve great success with 

its energy efficiency efforts. For more information about the 

company’s three-tiered energy audit model, read the Ingersoll 

Rand Success Story.

Brown Printing Company, headquartered in Waseca, Minnesota, features a 775,000-square-foot facility that 

prints approximately 200 weekly, bi-weekly, and monthly special 

interest publications, consumer publications, business-to-business 

publications, catalogs, and inserts for its national clientele. 

New to the U.S. Department of Energy Industrial Technologies 

Program Save Energy Now LEADER initiative, Brown Printing 

Company recently committed to reducing its facilities’ energy 

intensity 25% over the next 10 years.

Although only recently committing to the program, Brown 

Printing Company’s dedication to efficiency and conservation 

has been in place for several years. In 2008, Brown Printing 

Company received the Efficiency Partner Award from Xcel 

Energy for outstanding efforts in energy conservation. The award 

was presented after the Waseca facility achieved savings of 4.24 

million kilowatt hours (kWh) through the course of the 2008 

program. In 2010, Brown Printing Company was recognized as 

the CenterPoint Energy Customer of the Year for the company’s 

long-term dedication to energy efficiency in its business model. 

One method the company’s Waseca site is currently using to 

reduce its energy use takes advantage of its location—one hour 

south of Minneapolis—utilizing the cold weather to aid in the 

plant’s processes. During the harsh Minnesota winters, the chiller 

units on all of the company’s presses run on a “free” cooling 

chiller. In cold months, water is pumped to the roof—instead of 

a refrigeration unit—where it is cooled naturally. These systems 

save more than 2.4 million kWh per year, equivalent to the 

amount of energy used to power 225 homes.

Each of Brown Printing Company’s three facilities have 

implemented this free cooling method along with numerous other 

initiatives, including energy efficient lighting installation, variable 

frequency drives, computerized building management systems, 

and motion sensor lighting installation. With so many progressive 

steps being taken at each of Brown Printing Company’s facilities, 

the company received a 2010 Environmental Innovation Award 
ENERGY MATTERS / WINTER 2011

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from Unisource Worldwide, Inc. and WhatTheyThink for making 

real and concrete contributions to innovation, implementation, 

and communication of environmental solutions.

Brown Printing Company’s new pledge to join the Save Energy 

Now LEADER initiative marks another step toward meeting the 

company’s efficiency goals. 

For more information about the company’s energy efficiency 

efforts, visit http://www.bpc.com/environment. 

New Belgium Brewing Company: 

Alternatively Powered

New Belgium Brewing is an employee-owned regional craft brewery located in Fort Collins, Colorado. In July 

2010, New Belgium became 1 of 13 companies to make a 

voluntary commitment to improve the energy efficiency of its 

manufacturing facilities through participation in the Colorado 

Industrial Challenge (the Challenge)—a program co-sponsored 

by the Colorado Governor’s Energy Office and the U.S. 

Department of Energy.

As part of the Challenge, the brewery will receive technical 

assistance from Colorado State University’s Industrial 

Assessment Center and the ETC Group, an environmental 

engineering firm, to continue the energy efficiency efforts 

the company already has underway through the use of its 

Sustainability Management System—a system that requires 

the company to establish its current environmental impact, set 

specific targets for improvement, make plans to achieve those 

targets, and keep the plan/do/check/act cycle rolling.

As a company founded with sustainability in mind, New Belgium 

has already taken great strides to reduce its energy intensity and 

carbon footprint. In fact, one year the company’s employees 

unanimously voted to forgo holiday bonuses and instead invest 

the money into wind-powered energy, proving their commitment 

to social and environmental responsibility.

Some of the company’s main efforts to reduce energy use involve 

increased efficiencies in the brewing process and onsite energy 

production. New Belgium’s brew kettle was only the second of its 

kind installed in North America and is considered more efficient 

than standard brew kettles because it heats thin sheets of wort—

the liquid extracted from the mashing process during the brewing 

of beer—rather than the whole kettle at once. Additionally, the 

brewery uses the methane produced by process water treatment 

to fuel a combined heat and power engine—or co-gen—which 

creates electricity and heat for the brewery. 

To learn more about New Belgium’s environmental stewardship, 

visit http://www.newbelgium.com/culture/alternatively_

empowered.aspx.
ENERGY MATTERS / WINTER 2011

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DOE Grant Funds R&D Project to Improve the 

Efficiency and Productivity of Plastics Production

Recently, the U.S. Department of Energy’s Industrial Technologies Program (ITP) awarded Guided Wave Inc. 

of Rancho Cordova, California, with a $250,000 grant as part of 

the Industrial Energy Efficiency Grand Challenge—a funding 

opportunity announcement to support the development of 

transformational industrial processes and technologies that can 

significantly reduce the energy intensity and/or greenhouse gas 

emissions of U.S. industry. Guided Wave specializes in online 

optical measurements for process analytical chemistry and has 

served the polymer, chemistry, petroleum, pharmaceutical, 

sterilization, and semiconductor industries for more than 20 

years. 

The ITP grant will be assisting the company’s efforts 

in developing a new technology to monitor the color of 

polymers—a key ingredient in plastic manufacturing—during the 

high-heat, high-pressure extrusion process. Currently, if polymers 

are the wrong color, they are often recycled back through the 

extrusion process. Although this does save the material, the 

redundancy of the process uses extra energy and increases carbon 

emissions. 

The new device under development is meant to withstand the 

high heat and pressure inside an extruder. Being able to monitor 

coloring in this early stage of production will ensure the target 

color is reached without the need for an energy intensive and 

wasteful repetition of the process. 

Aside from the engineering challenges created by the high 

temperatures, high pressure, and low-light conditions involved 

in the polymer color process, Guided Wave says that high 

development costs is what has kept technology from advancing. 

ITP’s grant made Guided Wave’s research and development 

project possible, helping the company offer industry an energy 

saving advancement in a cost-effective way.

Guided Wave’s technology will enhance the production of an 

array of products—from detergent containers to plastic bottles. 

If developments are successful, the new technology could 

improve both productivity and energy efficiency in the 

manufacturing of plastics.

For more information about Guided Wave and the Industrial 

Energy Efficiency Grand Challenge, visit http://www.guidedwave.com/_pdf/news/PR_DOE_Award.pdf. 
ENERGY MATTERS / WINTER 2011

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States & Utilities Corner

Sherwin-Williams Partners with Kentucky’s 

Save Energy Now State Project to Facilitate Peer-toPeer Networking on Industrial Energy Efficiency Topics

On Friday, December 3, 2010, The Sherwin-Williams Company and Kentucky’s Pollution Prevention Center 

(KPPC) co-hosted the “Kentucky Energy Alliance Facility Tour 

and Roundtable.” As part of Kentucky’s Energy Alliance (KEA), 

the meeting brought 45 representatives from industry, health 

care, academia, and state agencies together at Sherwin-Williams’ 

Richmond manufacturing plant to share energy management 

best practices. During the meeting, attendees were provided 

the opportunity to converse with peers and discuss what their 

companies have been doing to improve energy efficiency. 

KEA is facilitating local networking between industrial and large 

commercial facilities that want to share information about energy 

efficiency resources. KPPC, based at the University of Louisville 

J.B. Speed School of Engineering, is leading Kentucky’s Save 

Energy Now program, providing resources and expertise to help 

deliver cost-saving energy efficiency solutions to industry, and 

supporting efforts to bolster KEA. Kentucky’s Save Energy Now

program is being funded through a three-year project award from 

the U.S. Department of Energy’s Industrial Technologies Program 

(ITP). As part of the program, KPPC developed its own statelevel “pledge” for businesses, industries, and other organizations 

to reduce their energy consumption by 2.5% annually for 10 

years. During the December event, KPPC described the various 

resources companies could utilize by participating in the 

statewide pledge program, including

• Assistance with developing energy baselines and energy 

management plans

• Access to energy assessments, training opportunities, and 

an energy management expert

• Access to proven energy analysis software tools and other 

DOE technical resources

• Statewide recognition for pledge participation and reported 

energy savings achievements.

Kentucky companies that take the pledge work toward achieving 

“five stars:”

1. Sign the pledge and develop an energy use baseline

2. Institute an energy management policy, establish a crossfunctional energy team, and attend energy management 

training

3. Assess operations for potential improvement opportunities 

and develop an energy action plan to reduce energy use by 

at least 2.5% each year

4. Implement the energy action plan and evaluate progress of 

the energy management program

5. Develop an internal recognition program and mentor other 

pledge participants.

Having Sherwin-Williams host the event seemed fitting. Not 

only was Sherwin-Williams the first company to sign Kentucky’s 

pledge, but it was also the first to achieve all “five stars.” 

Furthermore, the company’s Engineering, Maintenance, & 

Safety Manager, Gary Satler, has been actively recruiting other 

companies to participate in the program. As of January 2011, 20 

companies have joined the state’s pledge program.

In addition to the sharing of best practices, the December event 

also featured a tour of Sherwin-Williams’ plant and its utilities―

the cooling tower and boiler room. Several Sherwin-Williams 

employees showcased energy efficiency projects that were 

implemented as a result of the company’s employee suggestion 

system. For example, one employee-suggested project involved 

the installation of variable speed drive fans in the plant’s cooling 

tower. 

Additionally, at several locations throughout the plant, SherwinWilliams employees can find suggestion boxes where they can 

provide opinions and ideas. Each week, suggestions are reviewed 

and assigned to an “action manager” for follow-up. Employee 

suggestion topics have ranged from continuous improvement, 

cost savings, safety, recycling, lean operations, to energy. At the 
ENERGY MATTERS / WINTER 2011

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end of every year, the best ideas are selected for a cash award 

that amounts to a percentage of the implemented project’s 

resulting one-year savings. To date, Sherwin-Williams has 

experienced great success with its employee suggestion system. 

In its first year participating in ITP’s Save Energy Now LEADER 

initiative and Kentucky’s state pledge program, energy efficiency 

improvements at the company’s Richmond plant have reduced 

the site’s energy consumption by 26%.

Working together, the State of Kentucky and locally-based 

industries are improving their energy efficiency and economic 

competitiveness through peer-to-peer networking and the sharing 

of energy management best practices, program activities, and 

education.

For more information about Kentucky and other U.S. state 

activities, visit http://www1.eere.energy.gov/industry/states/

state_activities/main_map.asp. 

For more information about KPPC, visit https://louisville.edu/

kppc/. 

Tools of the Trade

The Energy Management Toolkit

The U.S. Department of Energy’s Industrial Technologies Program (ITP) is currently in the process of developing the 

Energy Management Toolkit. The forthcoming toolkit is a free 

integrated tool suite with two major components—technology 

solutions and an energy management portfolio. The technology 

solutions portion of the toolkit will comprise the plant-wide and 

system-specific software tools that are currently offered by ITP 

to help energy managers assess energy use and identify savings 

opportunities within their facilities. From the Quick Plant Energy 

Profiler to MotorMaster+, all of the tools needed to improve 

energy management at industrial facilities will now be available 

in one central location.

New to ITP’s software repository, the toolkit will feature the 

Energy Management System Implementation Self-Paced Module, 

a baseline energy management plan to help energy managers set 

timelines and develop strategies for meeting energy efficiency 

goals in their facilities. Because the tool is self-paced, it can be 

easily adapted to the needs and energy reduction goals of any 

user’s facility. Additionally, the energy management tool also 

provides plant managers with tips to help get employees engaged 

in efficiency measures, as well as pointers to assist in overcoming 

other roadblocks along the way to implementation. 

The Energy Management Toolkit is scheduled for release in late 

April 2011. More information on the toolkit will be available in 

the spring issue of Energy Matters.

Please visit http://www1.eere.energy.gov/industry/bestpractices/

software.html for more information about ITP’s software tool 

offerings.

Boiler room at the Sherwin-Williams Richmond, Kentucky, 

manufacturing plant.
ENERGY MATTERS / WINTER 2011

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Research & Development

Aerogel: Material of the Future Begins to 

Reach Its Commercial Potential

Aerogel is a lightweight, microporous material that has been around since the late 1920s. Recognized as having the 

highest insulation value of any known material, aerogel is also 

acknowledged for its ability to withstand extreme environments, 

decrease installation costs, reduce hazardous emissions, and 

reduce energy losses. However, even with these noted benefits, 

it wasn’t until recently that the material began to reach its 

commercial potential. 

The original production of aerogel—a supercritical drying 

method—though effective, was also dangerous, time-consuming, 

and expensive. Despite many companies’ research efforts, 

these factors led to the discontinued production and focus on 

aerogel in the 1970s. It wasn’t until the 1990s that researchers 

discovered safer, more efficient, and cost-effective manufacturing 

methods, allowing multiple industries to take advantage of the 

material’s unique characteristics. Today, there are two main 

approaches to making aerogel. First is a surface modification 

technique—a patented approach owned by materials company 

Cabot Corporation—that allows for subcritical liquid evaporation 

without significant gel shrinkage.1 The other method—developed 

by insulation manufacturer Aspen Aerogels—involves casting 

silica gel onto a fibrous batting and then supercritically drying the 

resulting blanket.2 Cabot Corporation and Aspen Aerogels are the 

only two companies to manufacture the product commercially. 

Today, there are a variety of applications for which aerogels are 

used. However, due to high manufacturing costs, aerogel has been 

primarily used in high-end industrial insulation applications in 

the oil, gas, and chemical industries. For instance, some of Aspen 

Aerogels’ first commercial contracts were to provide aerogel 

insulation for subsea oil transmission pipelines that go deep into 

the ocean.3

In order for aerogels to work in the high- and low-temperature 

environments required in industrial steam, fuel transport, and cold 

insulation applications, new formulations of the standard aerogel 

material had to be developed. In 2006, the U.S. Department 

of Energy’s Industrial Technologies Program (ITP) awarded 

Aspen Aerogels a research and development grant to develop 

an aerogel-based thermal insulation system for application to 

industrial steam distribution systems, including pipes, valves, 

traps, and other line components. With ITP assistance, Aspen 

Aerogels developed its Cryogel and Pyrogel aerogel systems 

for cold (-460°F) and hot (1200°F) insulation applications, 

respectively. Low-temperature applications include cryogenic air 

separation, liquefied natural gas storage, chilled water pipes, and 

petrochemical processing, while high-temperature applications 

include refineries, gas processing, and power plants. 

Aerogel-based pipe insulation performs a similar function 

as traditional steam pipe insulation systems, which employ 

mineral wool, fiberglass, calcium silicate, perlite, or various 

foams. However, as a flexible blanket material with intrinsic 

hydrophobicity, aerogel is not susceptible to the embrittlement 

or logging that deteriorates traditional materials. Additionally, 

aerogel significantly reduces the amount of material needed to 

perform the same thermal function, and can be doped to provide 

durable water repellency, mitigating one of the primary modes by 

which insulation degrades and energy is subsequently lost; this 

process also helps protect the pipelines from corrosion. 

Aerogel insulation has been successfully installed and used in 

plants around the world, including those of ExxonMobil, Suncor, 

Valero, and Chevron. ITP estimates that if aerogel insulation was 

applied to 40% of the 160,000 miles of U.S. industrial steam 

pipes, annual energy savings of 16 trillion British thermal units 

and energy cost savings of $117 million could be achieved by 

2025. 

While much of the market focus for aerogel has been on highend industrial applications, the product is beginning to reach a 

broader potential. Other emerging applications for the industrial 

and construction markets include 

• Structural composite insulation panels for commercial 

buildings

• Industrial and commercial insulation strips for heat and 

noise insulation

• Window insulating material for furnaces, kilns, 

spacecrafts, and commercial and residential buildings

• Shock-absorbing material

• Matting coatings for wear, corrosion, and thermal 

resistance in industrial applications.
ENERGY MATTERS / WINTER 2011

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Moreover, the material is now being used in unlikely quarters. 

For instance, the apparel industry is using aerogel to make 

insulated clothing for hikers, soldiers, firemen, and astronauts.

Commercial installations of the abovementioned applications 

include Kalwall installing structural panels in many locations 

across the United States, Burton Snowboards in Vermont and 

Corpo Nove in Italy selling aerogel insulated clothing, and the 

National Aeronautics and Space Administration developing 

Thermablok® as a spinoff for construction applications. Guardian 

Industries has also developed an aerogel containing vacuuminsulated glass system for windows, and others have developed 

glazing systems. Samsung recently partnered with Aspen 

Aerogels to begin selling the company’s insulation products for 

solar thermal applications.

Other installations include the Rhode Island Housing Authority’s 

use of Aspen Aerogels’ Spaceloft® in building retrofits; 

daylighting panels in Zurich, Switzerland; and Birdair’s roofing 

system at the Dedmon Athletic Center at Radford University in 

Radford, Virginia.

Future industrial applications currently under development 

include desalination, high-speed particle detectors, chemical 

sensors, hydrogen production or storage media, and 

supercapacitors.

In just a short period of time, the application and commercial 

viability of aerogel has reached unexpected heights. The 

material is penetrating new markets that before were considered 

impractical. We may not know what the next big market for the 

material will be, but it is clear from the numerous applications 

described here that aerogel has the potential to be a material of 

the future that can significantly impact residential, commercial, 

and industrial energy use.

Endnotes

1

 McCoy, M. (2010, Nov. 22). As Light As Air. Chemical & 

Engineering News 88(47), 18–19.

2

 Ibid.

3

 Ibid.

Implementation

Sherwin-Williams and Alcoa Discuss Strategies to 

Overcome Internal Barriers to the Implementation 

of Energy Efficiency Projects

Throughout 2010, the Industrial Technologies Program (ITP) presented two series of webcasts to provide 

industrial companies with peer-to-peer information regarding 

energy efficiency and implementation. During one of the ITP 

webcasts, Gary Satler (Manager of Engineering, Maintenance 

& Safety at The Sherwin-Williams Company) and Walter 

Brockway (Manager of Global Energy Efficiency at Alcoa, 

Inc.) provided information on the topic “Energy Efficiency 

Projects: Overcoming Internal Barriers to Implementation.” Each 

discussed how his respective company was able to surmount 

different energy and sustainability challenges. 
ENERGY MATTERS / WINTER 2011

12

At Sherwin-Williams’ Richmond, Kentucky, plant, the major 

hurdles to energy efficiency project implementation included 

access to capital, justification of projects, and allocation of staff 

resources. After implementing electricity projects that positively 

impacted the company’s budget, identifying an opportunity to 

reduce natural gas use by 25%, and forming a site energy team, 

the plant was able to consistently access capital for energy 

projects, justify the implementation of projects through proven 

results, and focus its high-level engineering and maintenance 

goals on energy and reliability. 

At Alcoa, the biggest obstacles to project implementation were 

gaining both high-level and low-level management support, 

creating an effective internal energy organization, raising 

employee awareness and involvement in energy activities, 

and obtaining funding for energy efficiency projects. After 

establishing a global energy efficiency team, Alcoa was able to 

execute a comprehensive energy efficiency program throughout 

the company. By holding monthly calls, leveraging internal and 

external resources, transferring knowledge amongst internal 

stakeholders, sharing company best practices, and exploring 

creative methods to implementing energy projects, the company 

was able to institute a new discipline and skill set that reduced its 

costs, energy intensity, and carbon footprint. 

While every company will face its own set of unique challenges 

to project implementation, Mr. Satler and Mr. Brockway 

addressed many of the internal barriers that all companies face, 

including securing capital and obtaining corporate buy-in. 

Through the establishment of energy teams and other strategies, 

Sherwin-Williams and Alcoa are two companies that have had 

great success overcoming these barriers. 

To access the slides and audio file from the Sherwin-Williams/

Alcoa webcast, visit http://www1.eere.energy.gov/industry/

resources/thursday_webcasts.html#mgt_finance. 

To access ITP’s library of industry webcasts, visit http://www1.

eere.energy.gov/industry/resources/webcasts.html. 

ITP Case Studies Highlight Industrial Efficiency 

Leaders; Share Best Practices

The Industrial Technologies Program (ITP) helps U.S. manufacturers improve their energy efficiency through the 

adoption of state-of-the-art technologies and energy management 

best practices. ITP offers tools, training, assessments, and many 

other resources to help industrial companies identify the most 

cost-effective options for saving energy—regardless of company 

size or level of energy management expertise. 

A number of companies have leveraged their partnership with 

ITP to identify and implement energy saving measures and, as a 

result, are experiencing significant annual cost savings, improved 

production, stronger competitiveness, and increased profitability. 

To help manufacturers learn from their industrial peers, ITP 

regularly produces case studies that feature such companies’ 

successful energy efficiency implementation projects and 

corporate energy management practices. 

Case studies provide the information needed to allow personnel 

from other facilities to analyze and determine whether or not a 

similar project or approach would be applicable and beneficial to 

their own plant(s). Case studies typically include the following 

details:

1. A pre-implementation profile/baseline information on the 

plant before it incorporated the new technology, process, 

and/or approach

2. A description of the problem at hand and how it was 

identified, the company’s decision-making process and 

rationale for addressing the problem, and the steps that 

were taken to find a solution

3. A detailed account of the technology, process, approach, 

and/or program implemented

4. An explanation of the benefits realized (e.g., energy and 

cost savings, payback periods, etc.). 

Featured case studies have detailed a multitude of energy 

management solutions, such as successful employee recognition 

programs, energy audit models, partnerships with government 

program offices, approaches to preparing for assessments, and 

effective corporate leadership practices. 
ENERGY MATTERS / WINTER 2011

13

Industrial Technologies Program IMPACTS

Success Story: 

Harrison Steel

Harrison Steel leverages both 

ENERGY STAR® and Save Energy 

Now programs to enhance 

energy efficiency efforts and 

multiply captured energy 

savings 

When Harrison Steel Casting Company 

made the decision to advance its 

energy efficiency efforts, the company 

took stock of the resources available 

to industry and made a strategic 

decision to partner with both the U.S. 

Environmental Protection Agency’s 

(EPA) ENERGY STAR® program 

and the U.S. Department of Energy’s 

(DOE) Industrial Technologies 

Program (ITP) Save Energy Now

LEADER initiative. Harrison Steel 

joined both of these programs 

because it allows the company to 

take advantage of the multitude 

of resources available from both 

ENERGY STAR and the Save Energy 

Now LEADER programs. Harrison 

Steel’s participation in both programs 

serves as an example that can be 

followed by other industrial companies 

interested in making improvements in 

energy efficiency. As Harrison Steel 

discovered, the programs differ in 

their scope and resources to provide 

complementary resources for industry. 

Where ENERGY STAR focuses on 

assisting companies in establishing 

effective energy management teams 

and corporate energy management 

programs, Save Energy Now LEADER 

offers technical expertise and assistance 

for successfully implementing 

efficiency improvements to industrial 

systems and processes. Industrial 

companies that are interested in 

INDUSTRIAL TECHNOLOGIES PROGRAM

reducing energy consumption and the associated costs should examine the results 

that Harrison Steel has realized by partnering with both the Save Energy Now and 

ENERGY STAR programs. 

Background

Harrison Steel Energy Manager Jeremy Allyn points to 2006 as the year that 

Harrison Steel began a clear commitment to energy reduction; that was the 

year when the company received an energy audit from Jack Staley of Balance 

Engineering. The audit produced a fairly extensive list of energy conservation 

measures. Although Harrison Steel did pursue some of the recommendations, the 

true value of that initial audit was opening the eyes of the company’s leaders and 

plant staff to the potential of realizing cost savings through the implementation of 

energy efficiency projects.1

Saving Energy to Improve the Bottom Line 

Energy costs at Harrison Steel typically constitute 5%-8% of sales.2 In 2008, the 

company was operating at full capacity, and it spent approximately $5 million on 

electricity and $4 million on natural gas. However, it should be noted that Harrison 

Steel’s natural gas costs were slightly above average that year due to the higherthan-normal prices at the time. The company’s electricity prices in 2008 were 6.8¢ 

per kWh with approximately 73.5 GWh of usage that year.3

 

In 2008, the average operating profit for steel foundries with more than $25 million 

in annual sales, such as Harrison Steel, was 6.6% of sales.4

 This slim profit margin 

is typical for steel foundries, and reducing operating costs through energy savings 

can help increase that margin and provide a competitive edge. Because rising energy 

costs can negatively affect profits, Harrison Steel understood that every dollar saved 

on energy spending would go directly to the bottom line. Additionally, the company 

understood that energy efficiency measures could have a more immediate impact. 

For example, a company with a profit margin similar to Harrison Steel’s that cuts 

energy spending by $66,000 through efficiency measures like lighting or stopping 

Harrison Steel facility where ductile iron is poured into casting molds

continued >

To see what other companies have done to increase their savings, 

read ITP’s most recent case studies:

• Ingersoll Rand Discovers Hidden Savings with a ThreeTiered Energy Audit Model

• Harrison Steel Leverages both ENERGY STAR® and 

Save Energy Now programs to enhance energy efficiency 

efforts and multiply captured energy savings

Additional case studies can be accessed on ITP’s website at 

http://www1.eere.energy.gov/industry/saveenergynow/case_

studies.html.

I

ndustry is the largest and most diverse energy-consuming 

sector in the U.S. economy. Each year, the Industrial 

Technologies Program (ITP) conducts research, development, 

and demonstration (RD&D) projects and technology transfer 

activities to address some of the nation’s biggest challenges in 

the areas of energy security and environmental performance. 

ITP tracks energy savings and other benefits associated with 

the successfully commercialized technologies that result from 

its research partnerships. This information is published in the 

Program’s IMPACTS Report. The IMPACTS document lists the 

ITP-sponsored technologies that are commercially available, their 

applications, and their benefits. It also details the impacts of ITP’s 

technical assistance initiative, Save Energy Now. 

Over the past 30 years, ITP has supported more than 600 

separate RD&D projects that have produced more than 200 

commercialized technologies. In 2008 alone, 104 of these 

successfully commercialized technologies resulted in industry 

saving 75.0 trillion British thermal units (TBtu) in energy 

costs. In addition to impressive energy savings, the industrial 

sector reaps even greater benefits from these technological 

advancements, including improved productivity, reduced resource 

consumption, decreased emissions, and enhanced product quality. 

In addition to its RD&D projects, one of ITP’s major efforts is 

the Save Energy Now program. Through this national initiative, 

ITP has developed a robust suite of energy saving tools and 

services to help industry improve its energy efficiency. The 

IMPACTS Report details the progress of technical assistance and 

implementation derived through Save Energy Now. For instance, 

as of September 2009, more than 1,500 industrial facilities have 

implemented recommendations identified during ITP-sponsored 

energy assessments. As a result, these companies have saved 

$218 million and 35 TBtu, and reduced their carbon dioxide 

emissions by 2.3 million metric tons each year.

To learn more about the technologies and programs that can help 

improve your plant’s performance, read ITP’s IMPACTS Report. 

Industrial Technologies Program: Summary of Program Results for CY 2008 

Boosting the Productivity and Competitiveness of U.S. Industry

IMPACTS

August 2010
ENERGY MATTERS / WINTER 2011

14

UTC’s Five-Pronged Approach 

to Energy Management

Dear Energy Expert:

My company recently issued a corporate directive to reduce our 

manufacturing facilities’ energy intensity. I am in charge of 

creating an energy management plan to help accomplish this 

objective. Can you explain what steps your company has taken 

to develop a successful energy management program?

United Technologies Corporation (UTC) is a diversified company that delivers high-technology products and 

services to commercial building and aerospace industries 

globally. With operations in approximately 180 countries, our 

business units include Carrier heating and air conditioning, 

Hamilton Sundstrand aerospace systems and industrial products, 

Otis elevators and escalators, Pratt & Whitney aircraft engines, 

Sikorsky helicopters, UTC Fire & Security systems, and UTC 

Power fuel cells. 

Energy management has been at the heart of UTC’s corporate 

culture since the late 1980s. It was during this time that the 

UTC Energy Council was formed to develop and share energy 

management best practices among business units. This paved the 

way for our five-pronged energy management approach, which 

has continuously improved since the 1990s. The plan consists 

of five components: a data collection and management system, 

policies and goals, an in-house energy team, energy assessments, 

and a project tracking system. All components are interrelated 

and, when brought together, form the framework of an energy 

management program that has enabled us to achieve substantial 

reductions in both energy intensity and absolute greenhouse gas 

(GHG) emissions.

Data Collection and Management System

UTC developed a centralized, Web-based environmental data 

collection and management system. The implementation of this 

system is vital to our company’s energy management agenda. 

Ask the Energy Expert

Ask the Energy Expert is an ongoing column with the intent of providing information and solutions for some of industry’s 

most pressing questions. This issue’s Energy Expert is Sean West, Environment, Health and Safety Project Manager at United 

Technologies Corporation. 

The most direct benefits of the system are visibility and 

consistency. First, when we turn raw data into useful information 

we can prioritize where we look for energy savings opportunities 

within our operations. Second, one cannot execute an energy 

management plan without having data in a consistent format. 

Having a centralized data system that individual facility managers 

can access via Web browsers, ensuring that all data is entered 

in standardized formats, enables UTC to overcome the inherent 

challenges that come with using spreadsheets. In addition, the 

accuracy of the data is essential. To improve data accuracy, UTC 

built error checking and intelligence functions into its system.

On January 26, 2011, UTC hosted the Save Energy Now

LEADER Showcase, “The Power of Partnerships,” at 

its Hamilton Sundstrand location in Windsor Locks, 

Connecticut. The Showcase brought together current 

and potential LEADER Companies, their suppliers, and 

U.S. Department of Energy representatives. During 

the event, UTC shared insights gained in meeting 

the company’s sustainability goals and talked about 

efforts to engage suppliers in establishing their own 

energy conservation programs. Participants also had 

the opportunity to tour the plant’s manufacturing 

operations, getting a closer look at the beneficial 

cost-saving technologies UTC has implemented. 

The event was ITP’s third Save Energy Now LEADER 

Showcase. The goal of these events is to demonstrate 

how industrial companies can increase their 

competitiveness through strategic partnerships and 

the implementation of energy efficient technologies 

and processes. Showcases also serve as a forum for 

industrial stakeholders to engage in peer-to-peer 

interaction, share energy management best practices, 

and learn from each others’ experiences.
ENERGY MATTERS / WINTER 2011

15

However, because our system has many geographically dispersed 

users, one challenge we faced involved training requirements. In 

addition to providing training for system users, UTC also made 

concerted efforts to automate the system to the highest extent 

possible. This helps the program run more self-sufficiently and 

reduces the amount of time spent on data entry. It’s important for 

data collection efforts to complement existing processes. This 

will further reduce training requirements and save both time and 

resources by only having to enter data once. By extension, the 

merging of data systems—such as accounting and environmental 

systems—is recommended, if possible. Furthermore, it is very 

important to set realistic boundaries when implementing a 

data management system. UTC’s original data system was first 

established in the company’s largest sites and then incorporated 

into other smaller sites. Today, the Web-based system collects 

energy and GHG data for over 300 manufacturing sites around 

the world and an estimate of energy consumption for thousands 

of small non-manufacturing sales and service locations.

Policies and Goals

With a system in place to measure and analyze energy use, 

goals can be set for reduction. The energy reduction goals must 

be supported by the highest level of management and become 

company policy. In this manner, energy reduction targets become 

part of the company’s operational goals.

In-House Energy Team

Knowledge sharing is a central element of UTC’s approach to 

energy management. As such, we created a cross-functional 

energy team—or an in-house resource of energy experts 

from different business units—to develop, communicate, and 

implement energy management best practices throughout the 

organization. Regardless of your organization’s size, an in-house 

energy team should be structured to accommodate differences 

among business units and individual manufacturing facilities. By 

doing so, in-house energy management teams avoid the pitfalls 

associated with generalizing needs based on organizational 

structure. In addition, the energy team should be encouraged 

to propose improvements to a corporate energy management 

plan, and conversely, corporate decision makers should regard 

an energy management plan as an evolutionary process that is 

constantly improving.

Energy Assessments

UTC’s energy management team provided the expertise needed 

to perform assessments at many of our manufacturing facilities. 

Normally, assessments are performed by two to four team 

members over a two-day period. With over 300 manufacturing 

facilities around the world, it became obvious that the energy 

team could not complete assessments at all sites. For this reason, 

UTC developed “The UTC Energy Management Guidebook” 

for use by onsite mangers. The guidebook, which is about 45 

pages in length, documents and shares energy management best 

practices that should be implemented in all facilities, both large 

and small. The purpose of the guidebook is to set a standard 

approach for managing energy at all UTC facilities. Topics 

covered in the guidebook include data management; utility rate 

reviews; procurement strategies; lighting efficiency; compressed 

air, boiler, and HVAC systems and controls. The output of the 

standardized approach is project identification.

Project Tracking System

UTC enters information about potential efficiency projects 

into a project tracking module that links to the aforementioned 

environmental data collection system. Entering information 

about a potential project allows us to tie it to and compare it 

against our company’s goals. This helps us determine whether 

the identified project will keep us on track to meet our goals. 

In addition, the project tracking module is instrumental in 

giving projects visibility so they can be reviewed by senior 

management. The real success of an energy management program 

is the implementation of projects. The project tracking module 

documents the energy savings for completed projects and 

maintains a list of projects pending approval.

Conclusion

At UTC, we pride ourselves on our commitment to performance, 

innovation, opportunity, responsibility, and results. We strive to 

maintain the highest environmental standards everywhere we do 

business. We have a strong history of setting environmental goals 

and pursuing them by continuously improving our processes at 

every level of the company. Through our five-pronged energy 

management approach, as well as our partnerships with other 

companies and governmental organizations—including the U.S. 

Department of Energy’s Industrial Technologies Program—UTC 

continues to identify, fund, and implement energy and GHG 

reduction projects that are generating noteworthy results.

“The real success of an energy management 

program is the implementation of projects.”
ENERGY MATTERS / WINTER 2011

16

International

The Alliance to Save Energy is hosting its annual Energy Efficiency Global Forum in Brussels, Belgium, April 12–14, 

2011. The event, now in its fourth year, brings together officials 

from government, industry, and nonprofit organizations to discuss 

trends and issues in energy efficiency. For more details, visit the 

Alliance to Save Energy’s website. 

Commerce Secretary Gary Locke recently launched the 

Renewable Energy and Energy Efficiency Export (RE&EE) 

Initiative. The effort, co-chaired by the Department of Commerce 

and Department of Energy (DOE), brings together eight federal 

agencies to coordinate efforts and boost exports in renewable 

energy and energy efficiency industries. The initiative will 

offer new and more innovative financing mechanisms for 

companies looking to expand abroad, increase the number of 

trade promotion events for RE&EE companies, direct agencies 

to improve export services in RE&EE, and lower trade barriers 

for RE&EE companies. This initiative will also help the United 

States meet President Obama’s goal of doubling exports by 2015. 

Visit www.export.gov/reee for more information. 

In December 2010, Secretary Chu attended the United Nation’s 

annual Convention on Climate Change Conference in Cancun, 

Mexico. Secretary Chu’s speech, “Building a Sustainable 

Energy Future,” covered recent federal investments in clean 

energy. He touched on a number of topics, including the 

Obama administration’s recent successful effort to raise vehicle 

efficiency standards for the nation’s automobile fleet, new DOE 

software tools to improve building efficiency, manufacturing tax 

credits for clean energy technologies, new appliance standards, 

and research in biomass energy.

Members of the Industrial Technologies Program (ITP) Steam 

Systems Best Practices program conducted a recent training 

workshop in Hyderdad and Pune, India. The three-day event 

educated local participants in DOE’s Steam System Tool 

Suite, including the Steam System Scoping Tool, the Steam 

System Assessment Tool, and 3E Plus®. During the workshop, 

participants practiced identifying steam system improvement 

opportunities and discussed recommendations with the entire 

class. Upon completion, participants received DOE certificates. 

This May, the United States will host high-level representatives 

from China for the 2nd U.S.-China Energy Efficiency Forum. 

The event—which is open to the public—will take place in 

Berkeley, California, and highlight energy efficiency cooperation 

and partnerships between the two countries. The first ever 

meeting took place last year in Beijing, bringing together more 

than 150 representatives from government, industry, academia, 

and nonprofit organizations. These meetings are a result of the 

Joint U.S.-China 10-Year Energy and Environment Cooperation 

Framework. To learn about the Cooperation Framework, visit 

http://www.pi.energy.gov/documents/10YearFramework.pdf. 

Funding Resources

The Office of Energy Efficiency and Renewable Energy (EERE) works with business, industry, universities, and 

others to increase the use of renewable energy and energy 

efficiency technologies. One way EERE encourages the 

growth of these technologies is by offering financial assistance 

opportunities for their development and demonstration. Visit the 

EERE Financial Opportunities website to learn about the EERE 

funding and award process, types of EERE financial assistance, 

and how to apply. 

The Industrial Technologies Program (ITP) offers many 

opportunities and activities for manufacturers who want to reduce 

their energy use and improve productivity. ITP uses Funding 

Opportunity Announcements (FOAs) to contract for cost-shared 

research and development. These opportunities reflect the 

priorities of the program and selection of projects follows meritbased criteria that emphasize projected energy, environmental, 

and economic benefits. Visit ITP’s website for active and future 

opportunities.
ENERGY MATTERS / WINTER 2011

17

Training Opportunities

February 28–March 21, 2011

Fundamentals of Compressed Air (Level 1); Four-Part Series

[Webinar]. This Web-based version of the popular Fundamentals 

of Compressed Air Systems training uses an interactive format 

that enables the instructor to diagram examples, give pop quizzes, 

and answer students’ questions in real time. Contact: Training 

Coordinator; info@compressedairchallenge.org.

March 2, 2011

Fundamentals of Compressed Air (Level 1) [Strattanville, 

Pennsylvania]. This is a 1-day introductory workshop designed 

to teach facility engineers, operators, and maintenance staff 

how to achieve 15%–25% cost savings through more effective 

production and use of compressed air. Contact: Shelly Luchini; 

814-375-4772; smc200@psu.edu. 

March 3, 2011

Motor Systems Management [Morgantown, West Virginia]. 

This 1-day workshop covers motor systems management, 

including applications, inventory tracking, maintenance, 

replacement decisions, repair, and the impact and maintenance of 

power quality. Contact: Kathleen Cullen; 304-293-2867;

Kathleen.cullen@mail.wvu.edu.

March 8–9, 2011 

Advanced Management of Compressed Air (Level 2)[Ann 

Arbor, Michigan]. This intensive 2-day workshop provides 

in-depth technical information on troubleshooting and making 

improvements to industrial compressed air systems. Contact: 

Brian LaFrence; 763-350-9397; lefrance@umich.edu.

March 16, 2011

Pumping Systems Assessment [Hazleton, Pennsylvania]. 

This 1-day workshop discusses performance problems 

encountered in everyday applications and presents the Pump 

System Assessment Tool (PSAT). Contact: Sally A. McGuire; 

570-450-3053; sam34@psu.edu.

March 18, 2011

Process Heating Systems Management [Dayton, Ohio]. This 

1-day workshop includes an introduction to process heating 

and process heating equipment, such as furnaces, ovens, dryers, 

heaters, kilns, etc. Contact: Ray Lepore; 937-216-9452;

ray.lepore@protogengroup.com.

March 22–23, 2011

Advanced Management of Compressed Air (Level 2)

[Louisville, Kentucky]. This intensive 2-day workshop provides 

in-depth technical information on troubleshooting and making 

improvements to industrial compressed air systems. Contact: Lisa 

Tatum Wease; 502-852-0148; lisa.tatumwease@louisville.edu.

April 12–13, 2011

Advanced Management of Compressed Air (Level 2)

[Louisville, Kentucky]. This intensive 2-day workshop provides 

in-depth technical information on troubleshooting and making 

improvements to industrial compressed air systems. Contact: 

626-812-7537; www.sce.com/workshops. 

April 15, 2011

Fundamentals of Compressed Air (Level 1) [Dayton, Ohio]. 

This is a 1-day introductory workshop designed to teach facility 

engineers, operators and maintenance staff how to achieve 

15%–25% cost savings through more effective production and 

use of compressed air. Contact: Ray Lepore; 937-216-9452; 

ray.lepore@protogengroup.com.

April 26, 2011

Fundamentals of Compressed Air (Level 1) [Omaha, Nebraska]. 

This is a 1-day introductory workshop designed to teach facility 

engineers, operators, and maintenance staff how to achieve 

15%–25% cost savings through more effective production and 

use of compressed air. Contact: Dennis Tribbie; 402-571-5004; 

dtribbie@hughesmachinery.com.

April 27–28, 2011

Advanced Management of Compressed Air (Level 2)

 [Omaha, Nebraska]. This intensive 2-day workshop provides 

in-depth technical information on troubleshooting and making 

improvements to industrial compressed air systems. Contact: 

Dennis Tribbie; 402-571-5004; dtribbie@hughesmachinery.com.

May 11, 2011

Process Heating Systems Management [Downey, California]. 

This 1-day workshop includes an introduction to process heating 

and process heating equipment, such as furnaces, ovens, dryers, 

heaters, kilns, etc. Contact: Larry Bennett; 562-803-7570; 

lbennett@semprautilities.com.
ENERGY MATTERS / WINTER 2011

18

 

Look for Us...

ITP Calendar of Events

Industrial Technologies Program Contacts

Click below to request more information about ITP and the services we provide.

 PARTNERSHIP DEVELOPMENT & DEPLOYMENT Paul Scheihing: paul.scheihing@ee.doe.gov; (202) 586-7234

 TECHNOLOGY DEVELOPMENT Stephen Sikirica: stephen.sikirica@ee.doe.gov; (202) 586-5041

March 2011

15–17: National Facilities Management & Technology Conference (NFMT)

30–31: Globalcon 2011

May 2011

14–18: 2011 MEP National Conference

May 18–June 8, 2011

Fundamentals of Compressed Air (Level 1); Four-Part Series

[Webinar]. This Web-based version of the popular Fundamentals 

of Compressed Air Systems training uses an interactive format 

that enables the instructor to diagram examples, give pop quizzes, 

and answer students’ questions in real time. Contact: Training 

Coordinator; info@compressedairchallenge.org.

May 20, 2011

Steam Systems Management [Dayton, Ohio]. This 1-day course 

covers the operation of typical steam systems and discusses 

methods of system efficiency improvement. Contact: Ray Lepore; 

937-216-9452; ray.lepore@protogengroup.com.
ENERGY MATTERS / WINTER 2011

19

The quarterly newsletter of the U.S. Department of Energy’s Industrial Technologies Program has been redesigned and expanded to 

include industry-related legislation and market trends, articles from industry experts, and other information of interest to our partners. 

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