Performance

Spotlight

Ford Van Dyke:

Compressed Air Management Program Leads to 

Improvements that Reduce Energy Consumption at an 

Automotive Transmission Plant

Project Summary

Between 2000 and 2003, staff at the Ford Van Dyke Transmission Plant (VDTP) 

in Sterling Heights, Michigan, increased the effi ciency of the plantʼs compressed 

air system. The plant has a rigorous compressed air management program that 

enables staff to maintain the compressed air systemʼs effi ciency and identify 

potential opportunities to reduce the amount of energy that the system consumes. 

After VDTP staff identifi ed opportunities for system improvements, a staff member 

from a U.S. Department of Energy (DOE) Allied Partner, Scales Air Compressor 

Corporation, helped to clarify some of the opportunities in a brief walk-through. 

Along with some planned equipment upgrades, improvement measures were 

implemented to improve the compressed air systemʼs performance, saving energy 

and improving production. Measures that were implemented between 2000 and 

2003 have resulted in energy savings of more than 1 million kWh for compressed 

air, and energy and maintenance cost savings of $165,000. The total cost of the 

planned upgrades and other measures was $336,000, yielding a 2-year simple 

payback.

Plant/Project Background

In operation since 1968, the VDTP is a 1.9-million-square-foot automotive 

transmission plant that produces more than 9 million car and truck transmission 

components annually. Compressed air is important at the VDTP for many 

pneumatic tools, stamping equipment, blow-off applications, and counterbalance 

cylinders. Plant personnel consulted with Scales Air Compressor Corporation to 

assess the system as part of a corporate initiative to improve energy effi ciency. That 

review confi rmed the benefi ts of eliminating unnecessary blow-off applications and 

air leaks as well as moisture carry-over, which resulted from a poorly functioning 

dryer that was near the end of its useful life and scheduled for replacement.

After the review, VDTP personnel moved forward with their anticipated compressed 

air system improvements. They began by replacing the ineffective dryer and 

conducting an aggressive and ongoing leak repair campaign. Plant personnel then 

eliminated the unnecessary blow-off applications and installed fl ow and dew point 

meters to accurately gauge the volume and quality of the air being generated. These 

measures helped to reduce pressure drop in the system, allowing the compressor 

discharge pressure to be lowered from 108 to 98 pounds per square inch gauge. 

Benefi ts 

• Saves $165,000 annually

• Reduces annual energy 

consumption by more than 

1 million kWh

• Increases production throughput

Industrial Technologies Program 

Proven Tools and Practices to 

Increase Industrial System Energy Effi ciency

Applications 

Almost any industrial facility can 

benefi t from having a compressed 

air management program. In 

many cases, projects identifi ed 

and implemented under such 

a program will reduce energy 

consumption and generate 

savings. In addition, these 

projects can help to improve 

production, reduce downtime, 

and trim maintenance costs.

Proven Tools and Practices to 

Increase Industrial System Energy Effi ciency
BestPractices is part of the Industrial 

Technologies Program, and it supports 

the Industries of the Future strategy. 

This strategy helps the country’s 

most energy-intensive industries 

improve their competitiveness. 

BestPractices brings together emerging 

technologies and energy-management 

best practices to help companies 

begin improving energy efficiency, 

environmental performance, 

and productivity right now.

BestPractices emphasizes 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.

A Strong Energy Portfolio 

for a Strong America

Energy efficiency and clean, renewable 

energy will mean a stronger economy, 

a cleaner environment, and greater 

energy independence for America. 

Working with a wide array of state, 

community, industry, and university 

partners, the U.S. Department 

of Energy’s Office of Energy Efficiency 

and Renewable Energy invests 

in a diverse portfolio of energy 

technologies.

FOR ADDITIONAL INFORMATION, 

PLEASE CONTACT:

EERE Information Center

1-877-EERE-INF

(1-877-337-3463)

www.eere.energy.gov

Visit our home page at

www.eere.energy.gov/industry

Industrial Technologies Program

Energy Efficiency and Renewable Energy

U.S. Department of Energy

Washington, DC 20585-0121

Results

The continuing optimization of the VDTPʼs compressed air system is yielding 

energy and maintenance cost savings while improving production. Total 

annual energy savings for compressed air are 1,075,000 kWh, and annual 

energy and maintenance costs are lower by $165,000. Even more important, 

product quality and process control have improved. Between 2000 and 2003, 

the plantʼs compressed air costs per unit of production declined by 18% and 

production increased by 2% as a result of the greater reliability and better control 

of compressed air to processes. The total cost of the improvement measures 

implemented during that time was $336,000, which results in a simple payback of 

just over 2 years. 

Lessons Learned

A rigorous compressed air management program that takes into account how 

various end-use applications within a plant use compressed air can lead to more 

efficient system performance and lower energy costs. An independent review 

validated the Ford VDTP staffʼs assumptions about their compressed air systemʼs 

energy consumption patterns and what was necessary to enhance the systemʼs 

energy efficiency. Their resulting actions did more than just save energy; they also 

strengthened an institutionalized management program that increased awareness 

about the systemʼs energy consumption, and this led to further improvements. 

In addition, they realized that trending compressed air use against production 

levels can be very useful in documenting system performance. Compressed air 

management programs such as this one can easily be implemented in industrial 

facilities that use compressed air.

Project Partners

Ford Motor Company

Sterling Heights, MI

Scales Air Compressor 

Corporation

Carle Place, NY

Partner Profile

William Scales, president of Scales Air Compressor Corporation, is an 

internationally recognized expert in compressed air systems. Over the 

last 40 years, he has visited more than 5,000 facilities and audited 

hundreds of compressed air systems throughout the world for a 

wide variety of industrial companies. He is a Qualified Instructor for 

the Compressed Air Challenge® (CAC) Fundamentals and Advanced 

Management training and was a member of the core group that developed this training. In addition, his company is a DOE Allied Partner.

CAC Instructors

The CAC qualifies instructors who are trained, certified experts in 

the use of compressed air systems. They are dedicated to providing 

industrial end-users with strategies they can implement immediately 

to improve the efficiency and reduce the costs associated with 

compressed air systems in their plants. 

William Scales

DOE/GO-102005-2081

May 2005