Industry Sector Resources
Do you want to reduce facility energy use?
Do you want to use energy more efficiently?
Do you want to reduce costs and save money?
Yes, yes, and YES! Improvements in industrial energy efficiency can yield significant savings in operating costs for manufacturers, which are especially important in difficult economic times.
Here, energy efficiency opportunities are organized by industry. Featured industry sectors are some of those which are specifically relevant to Michigan's economic base. However, the IAC can work with any industry in Michigan to help you reduce energy use and save money.
| Rank | Description | Average Annual Savings | Average Cost | Average Payback (years) |
| 1 | Utilize Higher Efficiency Lamps And/or Ballasts | $8,437 | $16,816 | 1.99 |
| 2 | Install Compressor Air Intakes In Coolest Locations | $1,943 | $1,230 | 0.63 |
| 3 | Eliminate Leaks In Inert Gas And Compressed Air Lines Valves | $6,010 | $2,289 | 0.38 |
| 4 | Use Most Efficient Type Of Electric Motors | $3,168 | $4,132 | 1.30 |
| 5 | Install Occupancy Sensors | $2,606 | $2,949 | 1.13 |
| 6 | Recover Heat From Air Compressor | $8,463 | $2,832 | 0.33 |
| 7 | Insulate Bare Equipment | $8,719 | $5,609 | 0.64 |
| 8 | Improve Air Circulation With Destratification Fans (or Other Methods) | $11,795 | $7,261 | 0.62 |
| 9 | Use Waste Heat From Hot Flue Gases To Preheat Combustion Air | $59,131 | $144,874 | 2.45 |
| 10 | Reduce Illumination To Minimum Necessary Levels | $4,207 | $2,024 | 0.48 |
Automotive and Transportation Equipment Manufacturing
There are 1,012 Automotive and Transportation Equipment Manufacturing establishments in Michigan.*Industries in the Automotive and Transportation Equipment sector produce components and equipment used in automotive manufacturing, and/or assemble automobiles from these components. Establishments in this subsector may utilize several production processes similar to those of other machinery manufacturing establishments - bending, forming, welding, machining, and assembling metal or plastic parts into components and finished products.
Industrial Assessment Center (IAC) teams around the U.S. have performed over 260 assessments of Automotive and Transportation Equipment Manufacturing facilities. These assessments have produced over 1,900 energy saving recommendations, with an average cost savings of $11,192 per recommendation over an average payback period of 1.2 years. View the recommendations and put this experience to work for you!
| Rank | Recommendation | Average Annual Savings | Average Cost | Average Payback (years) |
| 1 | Utilize Higher Efficiency Lamps and/or Ballasts | $16,137 | $32,929 | 2.04 |
| 2 | Eliminate Leaks in Inert Gas and Compressed Air Lines/Valves | $7,929 | $2,018 | 0.25 |
| 3 | Install Occupancy Sensors | $3,835 | $2,193 | 0.57 |
| 4 |
Reduce the Pressure of Compressed Air to the Minimum Required |
$3,955 | $923 | 0.23 |
| 5 | Install Compressor Air Intakes in Coolest Locations | $3,407 | $1,551 | 0.46 |
| 6 | Use More Efficient Light Source | $10,412 | $20,818 | 2.00 |
| 7 | Eliminate or Reduce Compressed Air Used for Cooling, Agitating Liquids, Moving Product, or Drying | $15,434 | $7,156 | 0.46 |
| 8 | Recover Heat from Air Compressors | $8,716 | $5,009 | 0.57 |
| 9 | Turn Off Equipment when Not in Use | $14,497 | $963 | 0.07 |
| 10 | Utilize Energy-Efficient Belts and Other Improved Mechanisms | $2,194 | $1,327 | 0.60 |
Already taking advantage of these recommendations? Then check out the Search by Assessments page on the DOE's Industrial Assessment Center (IAC) website to review energy assessment reports done for other facilities in your industry. In addition to the above-mentioned opportunities for energy savings, the assessments identify numerous other ways to save energy in primary metals manufacturing facilities including water use, recycling, industrial design, inventory, and space utilization.
Chemical Manufacturing
There are 408 Chemical Manufacturing establishments in Michigan*. Chemical Manufacturing is based on the transformation of organic and inorganic raw materials by a chemical process and the formulation of products. This sector includes the production of basic chemicals, and also production of intermediate and end products produced by further processing of basic chemicals.
Industrial Assessment Center (IAC) teams around the U.S. have performed over 250 assessments of Chemical Manufacturing facilities. These assessments have produced over 2,200 energy saving recommendations, with an average cost savings of $46,160 per recommendation over an average payback period of 2.0 years. View the recommendations and put this experience to work for you!
| Rank | Recommendation | Average Annual Savings | Average Cost | Average Payback (years) |
| 1 | Utilize Higher Efficiency Lamps and/or Ballasts | $7,388 | $15,049 | 2.04 |
| 2 | Eliminate Leaks in Inert Gas and Compressed Air Lines/Valves | $13,791 | $3,633 | 0.26 |
| 3 | Install Occupancy Sensors | $2,940 | $2,958 | 1.01 |
| 4 | Reduce the Pressure of compressed Air to the Minimum Required | $4,076 | $1,051 | 0.26 |
| 5 | Insulate Bare Equipment | $13,554 | $7,150 | 0.53 |
| 6 | Install Compressor Air Intakes in Coolest Locations | $2,735 | $1,100 | 0.40 |
| 7 | Use More Efficient Light Source | $8,533 | $15,950 | 1.87 |
| 8 | Use Multiple Speed Motors or AFD for Variable Pump, Blower, and Compressor Loads | $21,688 | $29,623 | 1.37 |
| 9 | Utilize Energy-Efficient Belts and Other Improved Mechanisms | $6,910 | $3,115 | 0.45 |
| 10 | Use Most Efficient Type of Electric Motors | $14,520 | $34,222 | 2.36 |
Already taking advantage of these recommendations? Then check out the Search by Assessments page on the DOE's Industrial Assessment Center (IAC) website to review energy assessment reports done for other facilities in your industry. In addition to the above-mentioned opportunities for energy savings, the assessments identify numerous other ways to save energy in primary metals manufacturing facilities including water use, recycling, industrial design, inventory, and space utilization.
Fabricated Metal Parts Manufacturing
There are 3,234 Fabricated Metal Parts establishments in Michigan*. Companies in the Fabricated Metal Product Manufacturing sector transform metal into intermediate or end products, or treat metals and metal formed products fabricated elsewhere. Important fabricated metal processes are forging, stamping, bending, forming, and machining, used to shape individual pieces of metal; and other processes, such as welding and assembling, used to join separate parts together.
Industrial Assessment Center (IAC) teams around the U.S. have performed over 480 assessments of Fabricated Metal Parts Manufacturing facilities. These assessments have produced over 4,000 energy saving recommendations, with an average cost savings of $10,642 per recommendation over an average payback period of 1.2 years. View the recommendations and put this experience to work for you!
| Rank | Description | Average Annual Savings | Average Cost | Average Payback (years) |
| 1 | Utilize Higher Efficiency Lamps and/or Ballasts | $9,806 | $19,312 | 1.97 |
| 2 | Eliminate Leaks In Inert Gas And Compressed Air Lines/ Valves | $7,857 | $1,927 | 0.25 |
| 3 | Reduce Pressure of Compressed Air to Minimum Required | $4,173 | $633 | 0.15 |
| 4 | Install Occupancy Sensors | $2,153 | $1,754 | 0.81 |
| 5 | Install Compressor Air Intakes In Coolest Locations | $2,724 | $1,133 | 0.42 |
| 6 | Use More Efficient Light Source | $7,526 | $9,670 | 1.28 |
| 7 | Insulate Bare Equipment | $7,065 | $2,870 | 0.41 |
| 8 | Utilize Energy-Efficient Belts and Other Improved Mechanisms | $3,343 | $4,268 | 1.28 |
| 9 | Eliminate Or Reduce Compressed Air Used For Cooling, Agitating Liquids, Moving Product, Or Drying | $8,430 | $5,717 | 0.68 |
| 10 | Use Most Efficient Type of Electric Motors | $4,852 | $9,602 | 1.98 |
Already taking advantage of these recommendations? Then check out the Search by Assessments page on the DOE's Industrial Assessment Center (IAC) website to review energy assessment reports done for other facilities in your industry. In addition to the above-mentioned opportunities for energy savings, the assessments identify numerous other ways to save energy in primary metals manufacturing facilities including water use, recycling, industrial design, inventory, and space utilization.
Food Manufacturing
Food Manufacturing There are 745 Food Manufacturing establishments in Michigan*. Comapnies in the Food Manufacturing sector transform livestock and agricultural goods into products for intermediate or final consumption. Manufactured food products are typically sold to wholesalers or retailers for distribution to consumers, but companies that sell bakery and candy products made on the premises not for immediate consumption are included.
Industrial Assessment Center (IAC) teams around the U.S. have performed over 450 assessments of Food Manufacturing facilities. These assessments have produced over 3,800 energy saving recommendations, with an average cost savings of $16,654 per recommendation over an average payback period of 1.3 years. View the recommendations and put this experience to work for you!
| Rank | Description | Average Annual Savings | Average Cost | Average Payback (years) |
| 1 | Utilize Higher Efficiency Lamps and/or Ballasts | $8,737 | $17,972 | 2.06 |
| 2 | Eliminate Leaks In Inert Gas And Compressed Air Lines/ Valves | $7,017 | $1,740 | 0.25 |
| 3 | Reduce Pressure of Compressed Air to Minimum Required | $3,754 | $878 | 0.23 |
| 4 | Install Occupancy Sensors | $2,473 | $3,194 | 1.29 |
| 5 | Use Most Efficient Type of Electric Motors | $6,130 | $11,697 | 1.91 |
| 6 | Insulate Bare Equipment | $9.411 | $5,583 | 0.59 |
| 7 | Use More Efficient Light Source | $6,171 | $13,542 | 2.19 |
| 8 | Utilize Energy-Efficient Belts and Other Improved Mechanisms | $4,622 | $3,783 | 0.82 |
| 9 | Install Compressor Air Intakes In Coolest Locations | $4,172 | $1,838 | 0.44 |
| 10 | Analyze Flue Gas for Proper Air/Flue Ratio | $12,003 | $6,315 | 0.53 |
Already taking advantage of these recommendations? Then check out the Search by Assessments page on the DOE's Industrial Assessment Center (IAC) website to review energy assessment reports done for other facilities in your industry. In addition to the above-mentioned opportunities for energy savings, the assessments identify numerous other ways to save energy in primary metals manufacturing facilities including water use, recycling, industrial design, inventory, and space utilization.
Machinery and Tool & Die Manufacturing
There are 2,301 Machinery and Tool & Die Manufacturing establishments in Michigan.* This sector is primarily made up of establishments that manufacture metalworking machinery, such as metal cutting and metal forming machine tools, cutting tools, accessories for metalworking machinery, special dies, tools, jigs, fixtures, industrial molds, rolling mill machinery, assembly mchinery, coil handling, conversion, and straightening equipment, and wire drawing and fabricating machines.
Industrial Assessment Center (IAC) teams around the U.S. have performed over 265 assessments of Machinery and Tool & Die Manufacturing facilities. These assessments have produced over 2,000 energy-saving recommendations, with an average cost savings of $10,157 per recommendation and an average payback period of 1.2 years. View the recommendations and put this experience to work for you!
| Rank | Description | Average Annual Savings | Average Cost | Average Payback (years) |
| 1 | Eliminate Leaks In Inert Gas And Compressed Air Lines/ Valves | $7,078 | $1,498 | 0.21 |
| 2 | Utilize Higher Efficiency Lamps and/or Ballasts | $11,802 | $29,382 | 2.49 |
| 3 | Reduce Pressure of Compressed Air to Minimum Required | $3,178 | $1,221 | 0.38 |
| 4 | Use More Efficient Light Source | $7,312 | $10,681 | 1.46 |
| 5 | Install Occupancy Sensors | $2,258 | $2,526 | 1.12 |
| 6 | Install Compressor Air Intakes In Coolest Locations | $1,896 | $820 | 0.43 |
| 7 | Utilize Energy-Efficient Belts and Other Improved Mechanisms | $2,399 | $1,129 | 0.47 |
| 8 | Turn Off Equipment When Not In Use | $15,429 | $336 | 0.02 |
| 9 | Recover Heat From Air Compressor | $5,917 | $2,578 | 0.44 |
| 10 | Eliminate or Reduce Compressed Air used for Cooling, Agitating Liquids, Moving Product, or Drying | $5,835 | $2,886 | 0.49 |
Already taking advantage of these recommendations? Then check out the Search by Assessments page on the DOE's Industrial Assessment Center (IAC) website to review energy assessment reports done for other facilities in your industry. In addition to the above-mentioned opportunities for energy savings, the assessments identify numerous other ways to save energy in primary metals manufacturing facilities including water use, recycling, industrial design, inventory, and space utilization.
Paper and Printed Materials
There are 178 Paper and Printed Materials establishments in Michigan*. Companies in the Paper and Printed Materials sector make pulp, paper, or converted paper products. The manufacturing of these products is grouped together because they constitute a series of vertically connected processes; more than one process is often carried out in a single establishment. There are essentially three activities: 1) pulp manufacturing; 2) paper manufacturing; and 3) manufacturing converted paper products (including cutting, shaping, coating, and laminating).
Industrial Assessment Center (IAC) teams around the U.S. have performed over 145 assessments of Paper and Printed Material Manufacturing facilities. These assessments have produced over 1,200 energy saving recommendations, with an average cost savings of $11,151 per recommendation over an average payback period of 1.2 years. View the recommendations and put this experience to work for you!
| Rank | Recommendation | Average Annual Savings | Average Cost | Average Payback (years) |
| 1 | Utilize Higher Efficiency Lamps and/or Ballasts | $11,993 | $21,971 | 1.83 |
| 2 | Eliminate Leaks in Inert Gas and Compressed Air Lines/Valves | $8,115 | $1,600 | 0.20 |
| 3 | Reduce the Pressure of Compressed Air to the Minimum Required | $7,153 | $1,145 | 0.16 |
| 4 | Utilize Energy-Efficient Belts and Other Improved Mechanisms | $4,499 | $1,698 | 0.38 |
| 5 | Install Occupancy Sensors | $2,267 | $2,842 | 1.25 |
| 6 |
Install Compressor Air Intakes in Coolest Locations |
$2,427 | $1,495 | 0.62 |
| 7 |
Insulate Steam/Hot Water Lines |
$9,403 | $3,855 | 0.41 |
| 8 | Use Most Efficient Type of Electric Motors | $8,967 | $34,097 | 3.80 |
| 9 | Use More Efficient Light Source | $7,950 | $19,062 | 2.40 |
| 10 | Insulate Bare Equipment | $18,785 | $5,509 | 0.29 |
Already taking advantage of these recommendations? Then check out the Search by Assessments page on the DOE's Industrial Assessment Center (IAC) website to review energy assessment reports done for other facilities in your industry. In addition to the above-mentioned opportunities for energy savings, the assessments identify numerous other ways to save energy in primary metals manufacturing facilities including water use, recycling, industrial design, inventory, and space utilization.
Primary Metal Manufacturing
There are 285 Primary Metal Manufacturing establishments in Michigan*. Companies engaged in Primary Metal Manufacturing smelt and/or refine ferrous and nonferrous metals from ore, pig or scrap, using electrometallurgical and other process metallurgical techniques. Primary metals manufacturing industries also manufacture metal alloys and superalloys by introducing other chemical elements to pure metals. The output of smelting and refining, usually in ingot form, is used in rolling, drawing, and extruding operations to make sheet, strip, bar, rod, or wire, and in molten form to make castings and other basic metal products.
Industrial Assessment Center (IAC) teams around the U.S. have performed over 245 assessments of Primary Metal Manufacturing facilities. These assessments have produced over 2,200 energy saving recommendations, with an average cost savings of $26,174 per recommendation over an average payback period of 1.2 years. View the recommendations and put this experience to work for you!
| Rank | Description | Average Annual Savings | Average Cost | Average Payback (years) |
| 1 | Utilize Higher Efficiency Lamps and/or Ballasts | $11,892 | $24,644 | 2.07 |
| 2 | Eliminate Leaks In Inert Gas And Compressed Air Lines/ Valves | $8,316 | $1,762 | 0.21 |
| 3 | Reduce Pressure of Compressed Air to Minimum Required | $7,373 | $4,289 | 0.58 |
| 4 | Install Occupancy Sensors | $3,144 | $4,765 | 1.49 |
| 5 | Use More Efficient Light Source | $9,241 | $19,338 | 2.09 |
| 6 | Install Compressor Air Intakes In Coolest Locations | $2,965 | $1,053 | 0.36 |
| 7 | Insulate Bare Equipment | $20,622 | $9,178 | 0.45 |
| 8 | Utilize Energy-Efficient Belts and Other Improved Mechanisms | $3,747 | $1,344 | 0.36 |
| 9 | Use Most Efficient Type of Electric Motors | $11,682 | $71,065 | 6.08 |
| 10 | Eliminate Or Reduce Compressed Air Used For Cooling, Agitating Liquids, Moving Product, Or Drying | $12,665 | $2,745 | 0.22 |
Already taking advantage of these recommendations? Then check out the Search by Assessments page on the DOE's Industrial Assessment Center (IAC) website to review energy assessment reports done for other facilities in your industry. In addition to the above-mentioned opportunities for energy savings, the assessments identify numerous other ways to save energy in primary metals manufacturing facilities including water use, recycling, industrial design, inventory, and space utilization.
Other Industries
* For each industry listed above there is key information and statistics about the industry, Top 10 lists of energy efficiency recommendations, and links to relevant case studies. The "Top 10" Energy Efficiency Recommendation lists were generated from the DOE's Industrial Assessment Center (IAC) database. The IAC database is a collection of all publicly available industrial energy assessment data generated by the university-based IAC assessment teams. As of August 2010, the IAC database contained 14,776 assessments and 110,132 recommendations! Check out the IAC Field Managers website for more energy efficiency ideas and recommendations, and further information about the Industrial Assessment Center program.
Additional Resources for Industrial Energy Information
EERE: Industrial Technologies Program Home Page
DOE's Industrial Technologies Program (ITP) helps industry save energy and money. If you are not familiar with the program, this is a good place to start. From this point you can learn more about Research & Development efforts, News and Events, and Features and Resources.
Industrial Technologies Program: Energy Intensive Industries
Part of the ITP program; provides extensive information on specific industries, energy savings opportunity by industry, and best practices.
Industrial Technologies Program: Information Resources
Part of the ITP program; access DOE's databases of energy assessment results and incentives programs, free online periodicals and news update e-mails, and technology videos.
Energy Innovation Portal Linking energy technologies with market opportunities. Find information on energy efficiency and renewable energy technologies available for licensing developed by U.S. Department of Energy laboratories and participating research institutions.
Industrial Assessment Centers Database
Searchable database of industrial energy assessments done at manufacturing facilities nationwide through the Industrial Assessment Center (IAC) program. Includes an index of recommendations and the ability to search by industry, state, recommendation type, implementation cost, and savings.
State of Michigan Department of Energy, Labor and Economic Growth
The State of Michigan's Bureau of Energy Services offers information on energy efficiency and renewable energy information for residential, commercial and industrial applications, including information on funding, technologies, and events.
American Council for an Energy-Efficient Economy: Industrial Sector Pages
ACEEE is a non-profit dedicated to advancing energy efficiency. Their Industrial Sector webpage includes information on Manufacturing Energy Policy and Programs, specific industrial technologies such as CHP and fuel cells, relevant publications, and news about research in the area of industrial energy efficiency.
Midwest Energy Efficiency Alliance MEEA is the leading source and champion for advancing sound energy efficiency policies, programs, and priorities to stretch our existing energy resources and reduce the need for imported energy solutions.
Compressed Air Challenge
Provides resources related to optimizing compressed air systems in industry.
Industry in Michigan
Industry is the largest and most diverse energy-consuming sector of the state's economy. As the home of the major U.S. automakers, it is not surprising that several of Michigan's major industries include those associated with transportation equipment. Michigan is also home to industries related to the production of food, chemicals, primary metals, and paper and printed materials.
IAC works hard to help Michigan industries reduce their manufacturing energy consumption and ultimately save money. We do this by connecting you to helpful online resources and tools, performing on-site energy assessments, and providing targeted training courses on industrial energy efficiency topics. Improving industrial energy efficiency will not only conserve resources and reduce costs for your company, but it will also promote a collectively stronger, more stable economy, a cleaner environment, and greater energy independence for Michigan.