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How did simple efficiency solutions help Husky save?

2 min read
Milton, VT

At Husky Injection Molding Systems, efficiency is critical to the business. Making technical injection molds relies on some heavy-duty machines that draw a significant amount of power. Reducing the power needed for that work directly impacts the company’s bottom line. Thanks to a close partnership with Efficiency Vermont over the course of a decade, Husky has reduced its power consumption at its Milton, VT plant by around 40%.

Identifying the opportunities

Before Husky could reduce energy use at the facility, the team first had to understand how much energy was being used, and by what. Husky worked with Efficiency Vermont to install submeters throughout the facility, taking precise measurements of energy usage and pressures across several pieces of equipment.

Through this work, the team identified two major opportunities for energy savings through simple operational changes. First, they found that the machinery was operating at far higher levels of power than it needed to for optimal performance. Second, they found that idling equipment was eating up power when it wasn’t needed at all.

“With every project we learn more about exactly how our facility operates, and we find more potential for improvement. As we look toward the future, I am confident we will continue to drive our energy cost per unit of production even lower – and our savings even higher.”

DeWayne Howell, Engineering, Maintenance, and Facilities Manager, Husky Injection Molding
Simple solutions yield big savings

Husky produces injection molds for the plastics industry. These molds are made by shaping metal, an extensive process that requires ready access to metal working fluids. In order to ensure that the fluids are available throughout the plant, Husky relies on a system of pipes and pumps to deliver the fluid to where it needs to go. Efficiency Vermont’s analysis of the sub metering data showed that Husky was generating a lot more pressure in this system than was necessary, even for times of peak production.

After running a test to ensure that lowering the pressure wouldn’t impact performance, the team lowered the pressure throughout the entire facility. They found that that the system still achieved the same high performance level to meet their manufacturing needs while using much less power. This relatively simple change is saving Husky an estimated $160,000 every year.

The submetering analysis also found that idling equipment was still drawing significant power. Turning that equipment off instead doesn’t impact production and is saving Husky another $40,000 each year. 

With every project, Husky says, the company learns how to further optimize energy use. It is part of the company’s commitment to continuous energy improvement and its ongoing partnership with Efficiency Vermont.