Case Study
Hexagon implements precise energy
management plan with EnerNOC
Demand response dispatches are almost invisible to Hexagon
Metrology—sensitive manufacturing continues ahead uninterrupted
Fast Facts:
Industry:
Manufacturing
Location:
North Kingstown, RI
Program:
EnerNOC DemandSMART-New England
DR Strategy:
Curtailment and backup generation
Primary Curtailment Strategy:
HVAC adjustments, lighting reductions
Annual Payments:
Approximately $15,000
© 2011 EnerNOC, Inc.
THE BIG PICTURE
Hexagon Metrology, Inc. is the North
American-based manufacturing, sales, service,
and distribution arm of The Hexagon Metrology
Group, the world’s largest manufacturer of
precision coordinate measuring systems.
Hexagon Metrology focuses on manufacturing,
sales, service, and distribution of micro
precision measuring products under the Brown
& Sharpe and TESA brand names. Its 112,000
square-foot facility in North Kingstown, Rhode
Island includes high-technology manufacturing
and assembly as well as office and warehouse
space—where more than 250 employees work
around-the-clock.
As a precision manufacturer with worldwide
reach and a reputation for quality, Hexagon
Metrology is focused
on maximizing efficiency and costeffectiveness, while acting as a leader within
its community. It has received a number of
major quality, workplace, and environmental
certifications, such as ISO 9001, ISO 14001,
and ISO 18001. In 2008, it began exploring the
potential of EnerNOC demand response (DR)
to reduce energy consumption to augment
its existing environmental and community
leadership efforts.
Hexagon Metrology combines lighting and
HVAC reductions and backup generation to
reduce energy consumption by 120 kW during
potential grid emergencies. The company
receives annual payments of approximately
$15,000 for its participation in DR—funds that
are used to pay for new projects that further
reduce energy use.
Case Study | Hexagon Metrology
THE RESULTS
Hexagon Metrology receives email and phone
notification of impending DR dispatches and
tests from EnerNOC. Once the notification
is accepted, EnerNOC automatically makes
adjustments via the company’s building
management system (BMS).
During a dispatch or test procedure:
• Approximately 50% of the company’s
lighting is turned off.
• Temperature set points in office areas are
raised from 72 degrees to 76 degrees.
John Mycroft,
Facilities, Environmental, Health and Safety Manager
A PRECISE APPROACH TO DR
Hexagon Metrology’s customers—major
U.S. automobile aircraft and defense
manufacturers, as well as other hightechnology firms—rely on the company’s
machines to provide exceptionally precise
measurements. Therefore, the company
cannot do anything that might jeopardize
the quality of its manufacturing processes;
however, company leaders are also
committed to reducing Hexagon Metrology’s
impact on the environment. Any adjustment
its existing processes must meet the dual
needs of high product quality and low
environmental impact.
energy-related costs. Once its facilities
personnel were settled into the new space,
the company began looking for other
opportunities to reduce energy use and
save money. “Even after our move to a new
facility, our electrical bill was still more
than $375,000 a year,” says Mycroft. “So
we were very open to EnerNOC’s demand
response story. Everyone here, from the
manufacturing staff to our executives, was
behind the idea of reducing energy, getting
paid for it, enhancing the environment, and
protecting our community. It seemed like an
obvious win-win for us.”
“Before we began talking to EnerNOC about
demand response, we were already actively
working to reduce our carbon footprint
and be as environmentally friendly as
possible,” recalls John Mycroft, facilities,
environmental, health and safety manager.
“We were very involved in meeting and
exceeding standards and staying at the
forefront of innovation and efficiency.”
Hexagon Metrology needed to protect a
key area of its manufacturing facility, a
10,000 square foot temperature-controlled
calibration room where its highly accurate
measurement devices are calibrated
under exact temperatures and conditions.
The temperature in this area is held to a
tolerance of +/- one-half degree Celsius.
No environmental program—no matter how
attractive—could jeopardize the precision
control over this room. “It’s the backbone of
our business,” says Mycroft. “Our customers
expect us to calibrate our machines under
precise tolerances. And we’re committed to
ensuring maximum quality and precision.”
In 2006, Hexagon Metrology moved to its
current facility in North Kingstown, Rhode
Island, a 112,000 square foot, customdesigned industrial space. This move saved
the company more than $500,000 in annual
© 2011 EnerNOC, Inc.
• Five of 10 rooftop HVAC units are shut off.
Hexagon personnel also manually shut
off other lights in office areas wherever
possible.
• EnerNOC automatically starts up Hexagon’s
onsite backup generator, which is used to
provide the sensitive calibration area with
a seamless, uninterrupted energy supply.
This strategy creates more than 120 kW of
energy reduction—50% from the heating
and lighting adjustments and 50% from the
use of backup generation.
“Most of our employees don’t even see the
changes, they’re almost invisible,” says
Mycroft. “The transfer to backup generation
is seamless, and the lighting changes are
virtually unnoticeable.”
At the end of a dispatch, EnerNOC returns
the BMS settings to their previous levels,
switches the backup generation off, and
operations go back to normal—all without
much effort by Hexagon Metrology staff.
“During a dispatch, we have very little to do
with the DR process,” says Mycroft. “Ninetynine percent of the process is automated,
which makes it incredibly easy for us to
participate.”
Manufacturing
For its participation in the emergency DR
program, Hexagon Metrology receives
approximately $15,000 a year in payments
from EnerNOC. “In addition to these payments,
we also use EnerNOC’s free PowerTrak®
energy monitoring to help reduce our energy
use by another $100,000 a year,” says
Mycroft. “By being more aware of our energy
use, we can make better-informed decisions
about our facilities’ energy use, which leads to
energy reductions and money savings.”
THE BENEFITS
EnerNOC DR enables Hexagon Metrology
to ensure the integrity of its temperaturecontrolled calibration room and the quality
of its products. This part of the company’s
facilities is protected from any changes,
since it moves seamlessly to backup
generation. Other areas, which are not as
critical, can accommodate lighting and HVAC
adjustments. With EnerNOC DR, Hexagon
Metrology gets the flexibility to control what
areas of its company are affected.
Other key benefits that EnerNOC DR brings to
Hexagon Metrology include:
AUTOMATED PARTICIPATION
EnerNOC’s ability to automate Hexagon’s
participation in DR takes much of the manual
work out of demand response. “Within a
few minutes, EnerNOC makes the changes,”
says Mycroft. “We just continue working.”
Every manufacturer should be a
part of demand response. Now that
companies have such a strong interest
in ‘going green,’ it really makes sense—
economically and environmentally.
John Mycroft,
Facilities, Environmental, Health and Safety Manager
This automated adjustment enables
Hexagon Metrology to continue ahead with
manufacturing, while leaving the DR details
to EnerNOC. After an event, EnerNOC returns
Hexagon Metrology’s facilities to their
normal settings.
PRECISION CONTROL
With EnerNOC controlling all adjustments
during DR events, Hexagon Metrology can be
confident that its sensitive facilities, such as
the calibration area, will continue without any
variations in temperature. EnerNOC carefully
monitors the Hexagon Metrology facilities to
ensure that all DR events run smoothly.
ADVANCED MONITORING
Hexagon Metrology receives free access
to energy monitoring features through
DemandSMART™, EnerNOC’s comprehensive
DR application. These tools help the company
keep a close eye on its energy use on an
ongoing basis. “In the past we used to just get
a monthly bill. Now we can monitor usage in
near real-time, making changes and tweaking
our energy use to raise energy efficiency.”
In all, Hexagon Metrology estimates that it
has saved more than $100,000 annually by
making adjustments to its facilities—all aided
and informed by EnerNOC software.
COMMUNITY SUPPORT
“EnerNOC demand response is good business
for us, and good for our community,” says
Mycroft. “It helps protect everyone from
brownouts and blackouts. It’s easy to do.
And we get paid for it. It’s a simple way to
be a good citizen of our community, and
What is Demand Response?
Demand response provides payments directly to organizations that choose to reduce
energy use during times of peak demand. EnerNOC DemandSMART is the industry’s most
comprehensive demand response application, allowing our customers to get the most
value from their participation in demand response programs throughout the US, Canada,
and the United Kingdom. EnerNOC works closely with customers to define customized
energy reduction strategies and ensure successful performance during events. EnerNOC
absorbs all costs and protects customers from any penalties that can be incurred for
not meeting reduction targets. Demand response helps stabilize your region’s energy
resources without requiring construction of new power plants—benefiting utilities, their
customers, and the environment.
Want More Information?
Hexagon Metrology is just one of the
many innovative organizations that
benefit from EnerNOC’s comprehensive
energy management applications.
To find out more, call (866) 366-7820 or
visit www.enernoc.com/get-started.
Case Study | Hexagon Metrology
Even after our move to a new facility, our electrical bill was still more
than $375,000 a year. So we were very open to EnerNOC’s demand
response story. Everyone here, from the manufacturing staff to our
executives, was behind the idea of reducing energy, getting paid for it,
enhancing the environment, and protecting our community. It seemed
like an obvious win-win for us.
John Mycroft,
Facilities, Environmental, Health and Safety Manager
we’re very proud to be a part of it.” Mycroft
is spreading the word about DR through
his local Chamber of Commerce, inspiring
manufacturers of all sizes to make DR part of
their company’s energy plans.
THE FUTURE
Hexagon Metrology continues to look for new
ways to boost its energy reductions during
DR events. It is pursuing a wide range of other
energy-related projects, including Leadership
in Energy and Environmental Design (LEED)
certification. Looking beyond Rhode Island,
the company hopes to enroll its other facilities
around the country in EnerNOC DR programs.
“Every manufacturer should be a part of
demand response,” concludes Mycroft.
“Now that companies have such a strong
interest in ‘going green’ it really makes
sense—economically and environmentally.”
EnerNOC, Inc. Headquarters
EnerNOC Ltd. Headquarters
EnerNOC UK Limited Headquarters
101 Federal Street
Suite 1100
Boston, MA 02110
Office: 617.224.9900
Fax: 617.224.9910
11-1155 North Service
Road West
Oakville, Ontario L6M 3E3
Office: 416.461.4678
Fax: 289.291.4001
Golden Cross House
8 Duncannon Street
London, WC2N 4JF
Office: +44 (0) 80. 0520. 0303
Fax: +44 (0) 80. 0520. 0192
EnerNOC, Inc. is headquartered in Boston, MA, United States, with wholly-owned subsidiaries in Canada (EnerNOC Ltd.) and the United Kingdom
(EnerNOC UK Limited). EnerNOC UK Limited is a company incorporated in England and Wales with company number 06937931, VAT number
GB980145422 and whose registered office is located at Alder Castle, 4th Floor, 10 Noble Street, London EC2V 7JX. A list of directors is available
for inspection at our offices.
© 2011 EnerNOC, Inc.
www.enernoc.com
For a full list of offices, please visit:
www.enernoc.com/about/contact.php
©2011 EnerNOC, Inc.
All rights reserved.
No text can be reprinted without permission.
Case Study
Linamar Makes DR a Green Initiative
Just-in-Time
Individual site evaluations bring custom curtailment plans
to 25 manufacturing sites
Fast Facts:
Industry:
Automotive and Diversified Manufacturing
Location:
Headquartered in Guelph, Ontario
EnerNOC Application:
DR Program:
EnerNOC DemandSMART™ Ontario
DR Strategy:
Curtailment
Primary DR Strategies:
Temporary shutdown of lighting, comfort
and charging stations
Annual Payments:
Hundreds of thousands of dollars
© 2011 EnerNOC, Inc.
THE BIG PICTURE
Based in Ontario, Linamar Corporation has
grown from a small machining operation
to a global supplier of vehicle and mobile
industrial equipment with 37 manufacturing
facilities worldwide. Linamar designs and
manufactures precision metal components
for the global vehicle and power generation
markets, as well as designs and produces
aerial work platforms and other equipment
for its industrial business segment.
As Linamar has grown, so has its yearly
energy usage. This dynamic presented a
paradox for the historically environmentallyconscious company; Linamar was eager
to minimize its energy usage as much as
possible but did not want to impede its
manufacturing operations. The customized
energy reduction plan proposed by EnerNOC
for its DemandSMART-Ontario program
was exactly the bespoke solution that
Linamar needed to participate in the Ontario
Power Authority’s DR3 scheme. EnerNOC
helped Linamar identify potential areas
for energy reductions while leaving critical
manufacturing processes untouched.
As a local expert with global backing,
EnerNOC had the most on-the-ground
knowledge of Ontario’s demand response
program, and, more importantly, the ability
to understand Linamar’s business and
match the two in a win-win partnership.
“EnerNOC has the most information,
the most up-to-date process knowledge,
and the most insight into the specifics
of demand response,” said Tony Luis,
Linamar’s Director of Purchasing.
For Linamar, this combination of process
expertise and local presence was essential.
Case Study | Linamar
Since joining the program, Linamar’s 25 plants have been dispatched an
average of six times per year and provide a total reduction of 2.4 MW.
CUSTOMIZED SITE-SPECIFIC
DEMAND RESPONSE
Linamar was keen to reduce energy usage
wherever possible, but with 25 separate
facilities across Ontario, knowing where
to begin was an intimidating challenge.
EnerNOC’s local experts made this
daunting task seem simple. In early 2009,
representatives from EnerNOC visited all
of the site managers at Linamar’s various
facilities. They conducted interviews and
determined what level of participation would
be right for each individual plant. “EnerNOC
took us through the process step-by-step,”
Luis recalled. “They met with each individual
plant, and explained what each site’s
involvement would be in a demand
response dispatch.”
EnerNOC outlined a curtailment plan for
each Linamar facility, met with each facility
manager to have it approved, and ran tests
at each site to make sure the reductions
would be effective during a demand response
dispatch. Ultimately, consensus was reached
across all 25 plants, and each one signed on
to its unique energy reduction plan.
THE RESULTS
Linamar’s two requirements for its plants’
curtailment plans were to 1) maintain
employee safety at all times, and 2) to allow
its manufacturing processes to continue
unimpeded. Therefore, when a demand
response dispatch occurs, Linamar practices
non-operational curtailment measures such
as reducing air conditioning in the plants’
front offices, dimming lights, and reducing
the air cycle schedule in the plants. Through
these measures, Linamar’s 25 plants provide
a total reduction of 2.4 megawatts (MW) per
dispatch. Since joining the program in 2009,
Linamar has been dispatched an average of
six times per year.
For Linamar, participating in demand
response with EnerNOC is straightforward.
Four hours before a dispatch begins,
EnerNOC contacts the designated point
person at each Linamar facility. The Linamar
contacts acknowledge the dispatch via email
or cell phone. The company then sends out
an internal email to let its staff know that
the dispatch is occurring. Two hours
before the actual dispatch, Linamar’s sites
implement their respective curtailment
plans. “We like to be proactive and make
sure we will be able to meet our goals.
We test this prior to the dispatch taking
place,” says Luis. From his computer,
Luis can monitor each site’s energy
consumption in real time via EnerNOC’s
DemandSMART™ online application,
ensuring that each site is meeting its
reduction targets. If he observes any one of
the 25 sites not adhering to its plan, Luis will
make a call to investigate. The dispatch lasts
exactly four hours.
THE BENEFITS
Linamar’s 2.4 MW reductions earn the
company hundreds of thousands in annual
payments from EnerNOC. In addition to these
financial benefits, Linamar has also enhanced
its own internal understanding of its various
plants, and increased its awareness of what
processes have the greatest impact on the
company’s energy usage.
EnerNOC demand response brings additional
benefits to the company as well, including:
EnerNOC has the most information, the most up-to-date
process knowledge, and the most insight into the specifics of
demand response.
Tony Luis, Director of Purchasing
© 2011 EnerNOC, Inc.
Automotive and Diversified Manufacturing
EnerNOC took us through the process
step-by-step. They met with each
individual plant, and explained what each
site’s involvement would be in a demand
response dispatch.
Tony Luis, Director of Purchasing
BUSINESS CONTINUITY
For most manufacturing companies, the
financial incentives from demand response
prompt them to pursue a full or partial
shutdown of manufacturing processes, while
the crew are deployed to other activities
like equipment maintenance. For Linamar,
though, EnerNOC was able to identify
substantial energy reductions outside of core
manufacturing processes so Linamar enjoys
the financial rewards of demand response
without disruption to its business.
BUSINESS INTELLIGENCE
EnerNOC’s DemandSMART™ technology
provides Linamar with a way to monitor
its disparate facilities from a central online
portal. Prior to working with EnerNOC,
Linamar had no way to visualize aggregated
energy usage data from individual facilities.
“Our plants were not connected to each
other at all,” noted Luis. “EnerNOC gave us
tools to help identify what processes in our
manufacturing have the greatest impact
on our energy use. Our plants are now
connected; we didn’t have that before.”
LOCAL SUPPORT
If a certain plant struggles to reach
expected reductions during dispatches,
EnerNOC visits that site to discuss
adjustments to its curtailment plan.
“EnerNOC is very involved in the process
of making DR work for each of our plants.
They are the experts in what is required to
meet our reduction goals,” Luis explained.
A COMPREHENSIVE APPROACH TO
SUSTAINABILITY
“A lot of our decision-making processes
are green-conscious,” said Luis. “The DR3
program is just another element of how we
do things here. We appreciate the financial
benefits but we also learn about our
business’ effect on our electricity usage.”
Often, individual plants will challenge
themselves to continue curtailment even
longer than the official dispatch period.
“We take certain measures to reduce
electricity during curtailment, but now
plants are asking themselves, ‘Can we do
these things over longer periods?’”
What is Demand Response?
Demand response provides payments directly to organizations that choose to reduce energy
use during times of peak demand. Demand response helps stabilize regional energy resources
without requiring construction of new power plants—benefiting utilities, energy users, and
the environment. EnerNOC DemandSMART™ is the industry’s most comprehensive demand
response application, allowing businesses to get the most value from their participation in
demand response programs throughout Australia, the United States, Canada, and the United
Kingdom. EnerNOC works closely with organizations to define customized energy reduction
strategies and ensure successful performance during dispatches. EnerNOC absorbs all costs
and protects program participants from any penalties that may be incurred for not meeting
reduction targets.
Want More Information?
Linamar is just one of the many
organizations that benefits from
EnerNOC’s comprehensive energy
management applications.
To find out more, call (866) 366-7820 or
visit www.enernoc.com/get-started.
Case Study | Linamar
EnerNOC gave us tools to help identify what processes in our
manufacturing have the greatest impact on our energy use.
Our plants are now connected; we didn’t have that before.
Tony Luis, Director of Purchasing
THE FUTURE
Linamar recently renewed its contract
with EnerNOC so that it will continue to
understand its own energy usage and
reap financial benefits at the same time.
Why else? EnerNOC makes it easy. Says Tony
Luis: “EnerNOC stays on top of things and
communicates with us; they are very active
and involved.” With its hands-on, customized
approach, strong local connections with
Ontario’s utilities, and global technical
expertise, EnerNOC takes the guess-work
out of demand response.
EnerNOC’s experts visited each of Linamar’s 25 sites and helped determine the
appropriate level of demand response participation for each individual plant.
EnerNOC, Inc. Headquarters
EnerNOC Ltd
EnerNOC UK Limited
EnerNOC Pty Ltd
101 Federal Street
11-1155 North Service
Golden Cross House
45 Ventnor Avenue
Suite 1100
Road West
8 Duncannon Street
West Perth W.A. 6005
Boston, MA 02110
Oakville, Ontario L6M 3E3
London, WC2N 4JF
Office +61-(0) 8-9429.8860
Office: 617.224.9900
Office: 416.800.0948
Office +44 (0) 80. 0520. 0303
Fax +61-(0) 8 9429.8800
Fax: 617.224.9910
Fax: 289.291.4001
Fax +44 (0) 80. 0520. 0192
EnerNOC, Inc. is headquartered in Boston, MA, United States, with wholly-owned subsidiaries in Canada (EnerNOC Ltd.), the United Kingdom
(EnerNOC UK Limited), and Australia (EnerNOC Pty Ltd). EnerNOC UK Limited is a company incorporated in England and Wales with company
number 06937931, VAT number GB980145422 and whose registered office is located at Golden Cross House, 8 Duncannon Street, London WC2N
4JF. A list of directors is available for inspection at our offices.
© 2011 EnerNOC, Inc.
www.enernoc.com
For a full list of offices, please visit:
www.enernoc.com/about/contact.php
©2011 EnerNOC, Inc.
All rights reserved.
No text can be reprinted without permission.
Case Study
Rio Tinto Minerals Mines the Many Benefits
of Demand Response with EnerNOC
Major mineral supplier enrolls large mining and processing facilities as
part of its commitment to sustainability
Fast Facts:
Industry:
Mining/Manufacturing
Location:
Houston, TX and Ludlow, VT
Program:
EnerNOC DemandSMART
–Emergency Response Service
EnerNOC DemandSMART
–New England
DR Strategy:
Curtailment only
Energy Reduction Strategy:
Selected shutdowns of talc
processing equipment
Annual Payments:
Approximately $36,000
© 2010 EnerNOC, Inc.
THE BIG PICTURE
Rio Tinto is one of the largest industrial
minerals suppliers in the world, with
mining and processing facilities in the U.S.,
South America, Europe, and Asia. It serves
nearly 2,500 customers, accounting for
half the global demand for refined borates
and about 20 percent of the global
demand for talc. Rio Tinto has made a
significant and public commitment to
responsible stewardship of its resources
and sustainable development. It works
hard to be a good business partner and
neighbor, minimizing environmental
impact while providing valuable products
to a wide range of industries.
Rio Tinto’s Luzenac brand of talc
represents the highest-quality talc
products on the market. Talc—the earth’s
softest mineral—possesses a unique
combination of properties that make it
invaluable in wide-ranging applications,
from paint and paper to personal care
products and pharmaceuticals.
In 2006, one of Rio Tinto’s talc operations
in Ludlow, Vermont enrolled in demand
response (DR) with EnerNOC, attracted by
the opportunity to earn payments while
helping contribute to the stability of the
energy grid and overall sustainability. It
achieves reductions of almost 700 kilowatts
(kW) by temporarily shutting down elements
of its talc processing operation—earning
annual payments of more than $16,000 from
EnerNOC. Inspired by the success of demand
response at this facility, Rio Tinto enrolled its
Houston, Texas talc facility in 2008, reducing
energy use by 1 megawatt (MW) and earning
approximately $20,000 a year.
Case Study | Rio Tinto
economic times. “We couldn’t be happier
with EnerNOC and demand response,” Kopp
says. “We’re thrilled with the program and
glad to be a part of it.”
With EnerNOC, Rio Tinto’s Houston, TX facility supports its
communities and contributes to overall sustainability while
earning significant payments in challenging economic times.
TAKING ADVANTAGE OF EXCESS
CAPACITY
Most people know talc from popular
consumer products, such as talcum powder
and cosmetics. But talc is one of those
hidden commodities that plays a critical role
in a wide range of industrial and consumer
products—including shingles, paint,
pharmaceuticals, and personal care products.
After being mined from the ground, talc is
crushed, milled, and classified into different
grades appropriate for various applications.
The roller mill systems that are at the heart of
talc processing require a significant amount
of energy, making electricity one of the top
expenses of these operations. “We’re always
looking for ways to reduce energy use,” says
Tim Hicks, technical and process manager
at Rio Tinto/Luzenac America’s Ludlow,
Vermont mill. “If we can lower the overall peak
kilowatts we’re using, that’s good news for our
business.” For example, each of the four roller
mill systems in this Rio Tinto operation draws
350 kilowatts of electricity.
The opportunity to earn significant payments
from EnerNOC by temporarily reducing
energy use held a strong appeal for Hicks
and the rest of the Rio Tinto team when
they first heard of EnerNOC and DR in 2006.
© 2010 EnerNOC, Inc.
But their interest wasn’t just in the financial
benefits. “We also wanted to support the
various communities where our facilities are
located,” recalls Jim Kopp, a director who
supervises the Vermont and Texas mills, as
well as other operations.
For Kopp and other executives, DR is part
of broader commitment to sustainability,
one defined in the company’s extensive
annual Sustainable Development Report.
By participating in DR with EnerNOC, Rio
Tinto can support its communities and
contribute to overall sustainability—while
earning significant payments in challenging
EnerNOC and Rio Tinto began their
partnership by carefully evaluating the
Vermont site’s energy use and exploring
potential methods of reducing energy. This
large-scale operation includes mining as well
as manufacturing, enabling it to achieve a
maximum capacity of 250,000 tons. The team
determined that mining needed to continue
ahead uninterrupted. So for their energy
reduction plan, they instead focused on the
manufacturing side of the business, and
more specifically, the roller mills—the major
energy-consuming machinery. The result?
EnerNOC helped Rio Tinto create a plan that
works for them, and that defines how to
respond during a demand response event.
EnerNOC worked closely with Hicks and
his team to integrate DemandSMART,
EnerNOC’s comprehensive demand response
application, with the mill’s central control
room. “We were already monitoring our
demand, setting limits on how much
electricity we could use, and controlling our
peak use,” recalls Hicks. “So DemandSMART
was a natural extension of how we were
already monitoring and managing our energy
use for maximum efficiency, and to lower
costs. Only now, we’re getting paid for it.”
“ The demand response events are
so infrequent that we really don’t
think about it that much. With
EnerNOC, demand response all
happens automatically.
Mike Hare, Process Engineer
Manufacturing
During a demand response event, Hicks
and his team receive advance notice from
EnerNOC via phone and email. “We’re all in
contact and well aware of what we need to
do,” says Hicks. Within ten minutes, the mill
is temporarily shut down, and crews turn to
maintenance, cleaning, and other tasks.
Flexibility in the milling process enables
the milling operation to suspend
processing temporarily without affecting
the overall business. “We have excess
capacity that keeps our silos full of
processed talc and enables us to keep
meeting the needs of our customers,”
says Hicks. “We can shut down
manufacturing without any real
effect, while we continue mining.”
Encouraged by the results in Vermont, a
second talc processing facility in Houston,
Texas enrolled in DR with EnerNOC in 2008.
This operation is similar to the Vermont
facility, but involves processing exclusively,
not mining. Energy reductions at this facility
also involved shutting down selected roller
mills as well as secondary milling equipment.
However, in this case, EnerNOC automatically
shuts them down remotely from its Network
Operations Center (NOC).
“Our control room isn’t manned 100 percent
of the time,” explains Mike Hare, process
engineer at Luzenac America/Rio Tinto’s
“ I recommend demand response
with EnerNOC highly. It’s a great way
to control costs while contributing to
overall sustainability.
Jim Kopp, Director
Houston mill. “EnerNOC’s automatic control
option ensures that we can respond quickly
when necessary.” These shutdowns are
temporary, lasting a maximum of eight
hours during peak energy periods.
Like the Vermont facility, Rio Tinto’s
Houston site uses any downtime to pursue
maintenance and other on-site work. And
it relies on its stock of stored talc to provide
the flexibility it needs to temporarily
suspend manufacturing.
During several years of demand response
events, the Vermont facility has consistently
met and exceeded its reduction target.
“The events have been very positive,” says
Hicks. “They went well, and we got back to
normal without any problems at all.”
Hare agrees. “The demand response events
are so infrequent that we really don’t think
about it that much,” he says. “With EnerNOC,
demand response happens automatically.”
THE BENEFITS
THE RESULTS
During DR events, Rio Tinto can reduce
energy use by an average of 690 kW at
its Ludlow, Vermont facility and 1 MW at
its Houston, Texas site. These reductions
earn the sites significant annual payments
from EnerNOC—approximately $16,000 for
Vermont and $20,000 for Texas.
What is Demand Response?
Demand response provides payments directly to organizations that choose to reduce
energy use during times of peak demand. EnerNOC DemandSMART is the industry’s most
comprehensive demand response application, allowing our customers to get the most
value from their participation in demand response programs throughout the US, Canada,
and the United Kingdom. EnerNOC works closely with customers to define customized
energy reduction strategies and ensure successful performance during events. EnerNOC
absorbs all costs and protects customers from any penalties that can be incurred for
not meeting reduction targets. Demand response helps stabilize your region’s energy
resources without requiring construction of new power plants—benefiting utilities, their
customers, and the environment.
The combination of payments and a
commitment to sustainability is vital to
the success of demand response at these
Rio Tinto mining/manufacturing sites. But
most importantly, the sites can participate
in demand response without affecting their
overall operation, or their customers. “We
have plenty of capacity and talc in storage,so
we always have what our customers want,”
says Hare. “And with EnerNOC, demand
response is almost invisible.”
Want More Information?
Rio Tinto is just one of the many
innovative organizations that benefits
from EnerNOC’s comprehensive
energy management applications.
To find out more, call (866) 366-7820 or
visit www.enernoc.com/get-started.
Case Study | Rio Tinto
DemandSMART was a natural extension of how we
were already monitoring and managing our energy use
for maximum efficiency, and to lower costs. Only now,
we’re getting paid for it.
Tim Hicks, Technical and Process Manager
EnerNOC brings a range of powerful benefits
to the company:
A SIMPLE, STREAMLINED PROCESS
bringing DR into its manufacturing operations
was simple for Rio Tinto. “EnerNOC really
drove the whole process,” says Hare. “From
explaining to contracts and implementation
to testing, the whole process was easy.”
A CHOICE OF CONTROL
The Vermont and Texas facilities represent
two different approaches to responding
to demand response events. The Vermont
facility manually shuts down key equipment,
while in Houston, EnerNOC makes automatic
adjustments to the operation remotely, via
the central control system. “At first, I was a
little skeptical about automatically shutting
down, but it really works for us,” says Hare.
“The risk is minimal to us. And there are
no penalties.”
FREE AUDITING AND MONITORING
During implementation, EnerNOC installed
free monitoring equipment and access
to its DemandSMART application, which
supplemented Rio Tinto’s existing monitoring
efforts. The DemandSMART application
enables the company to measure and
monitor energy consumption in real time,
during demand response events and beyond.
Now each site has a clear window into its
ongoing energy use.
LEVERAGING CAPACITY
Both Rio Tinto facilities have flexibility
within their production operations that
enables temporary suspension of talc
manufacturing. Taking advantage of this
flexibility enables Rio Tinto to participate in
DR with EnerNOC without affecting its overall
ability to meet the needs of its customers.
“In some cases, we actually benefit from
being able to shut down temporarily,” says
Hicks. “And it’s really easy for us to get back
to normal operations after events.”
SUPPORTING THE COMMUNITY
DR programs help ensure the reliability of the
energy grid during peak periods by reducing
demand. By participating, Rio Tinto meets a
key commitment of its Sustainability Policy—
helping protect and improve the communities
in which it operates. “Our company has specific
targets for community support,” says Kopp.
“DR with EnerNOC helps us meet them.”
THE FUTURE
Rio Tinto continues to explore implementing
DR with EnerNOC at other manufacturing
facilities that have the flexibility and capacity
to shut down, partially or completely, for a
temporary period. “I recommend demand
response with EnerNOC highly,” says Kopp.
“It’s a great way to control costs while
contributing to overall sustainability.”
EnerNOC, Inc. Headquarters
EnerNOC Ltd. Headquarters
EnerNOC UK Limited Headquarters
101 Federal Street
Suite 1100
Boston, MA 02110
Office: 617.224.9900
Fax: 617.224.9910
11-1155 North Service
Road West
Oakville, Ontario L6M 3E3
Office: 416.461.4678
Fax: 289.291.4001
Alder Castle, 4th Floor
10 Noble Street
London EC2V 7JX
Office: 0800.520.0303
Fax: (0)800.520.0192
EnerNOC, Inc. is headquartered in Boston, MA, United States, with wholly-owned subsidiaries in Canada (EnerNOC Ltd.) and the United Kingdom
(EnerNOC UK Limited). EnerNOC UK Limited is a company incorporated in England and Wales with company number 06937931, VAT number
GB980145422 and whose registered office is located at Alder Castle, 4th Floor, 10 Noble Street, London EC2V 7JX. A list of directors is available
for inspection at our offices.
© 2010 EnerNOC, Inc.
www.enernoc.com
For a full list of offices, please visit:
www.enernoc.com/about/contact.php
©2010 EnerNOC, Inc.
All rights reserved.
No text can be reprinted without permission.
Case Study
Vapor Tech Makes Demand Response with
EnerNOC Part of Manufacturing Process
Innovative manufacturer reduces costs by making temporary
adjustments to its production line
Fast Facts:
Industry:
Manufacturing
Location:
Longmont, CO
Program:
Xcel Energy–EnerNOC Peak Savings
DR Strategy:
Curtailment only
Energy Reduction Strategy:
Selected manufacturing process
shutdowns
Annual Payments:
Approximately $5,000
© 2010 EnerNOC, Inc.
The Big Picture
Vapor Technologies, Inc. is a leader in the
science, development, production, and
application of Physical Vapor Deposition
(PVD) equipment, which deposits thin
metalized films onto various surfaces.
Vapor Tech’s advanced, proven coating
technologies play a key role in a wide
range of applications—from coating
plumbing products (such as faucets)
with a brilliant, durable finish to critical
uses within the medical products and
alternative energy markets. Vapor
Tech leverages its coating systems and
technologies to bring a competitive
advantage to their consumer products.
In 2009, the company implemented
demand response (DR) with EnerNOC,
intrigued by the opportunity to
earn payments by making temporary
adjustments to its manufacturing operation.
Now Vapor Tech shuts down selected
elements of its operations during DR events,
reducing its energy use by more than 200
kilowatts (kW). This reduction earns the
company approximately $5,000 in annual
payments from EnerNOC—while protecting
the local energy grid and the environment.
Additionally, DemandSMART™, EnerNOC’s
comprehensive demand response
application, gives Vapor Tech real-time
visibility into its energy consumption and
DR event performance.
Case Study | Vapor Technologies
within the production line that could be shut
down temporarily to trigger energy reductions.
The result is a clear plan captured in a simple
one-page checklist that defines the areas
that can be adjusted and identifies the person
responsible for taking action. The plan consists
of energy reductions that include:
• Shutting down PVD systems that are
not in use
• Shutting down a cleaning line
• Reducing use of air conditioning
throughout the facility
• Eliminating unnecessary lighting (e.g., in
empty offices and areas with natural light)
During a DR event, Vapor Tech makes adjustments to its
operation without any overall impact on the company.
A business built on electricity
At Vapor Tech’s 60,000 square-foot
headquarters and manufacturing facility in
Longmont, Colorado, electricity is much more
than a commodity. It’s at the heart of Vapor
Tech’s coating technologies. A low-voltage,
high-current arc is the key element that
enables coating of metallic parts during the PVD
process. So Vapor Tech leaders are very aware
of the critical need for using energy wisely,
and conserving whenever possible. After all,
the company’s core technology—and ongoing
success—depends on a reliable, available, and
cost-effective supply of electricity.
• Shutting down unnecessary equipment
in its labs
operation,” he says. “But there are definitely
areas where we can make adjustments,
and certain systems that we can shut down
without any overall impact on the company.”
Working closely with Vapor Tech, EnerNOC
helped create an overall energy reduction
plan for the facility. They began by evaluating
the entire manufacturing operation and
identifying key power-consuming devices
Like many manufacturing operations, Vapor
Tech adjusts its production line based on
volume requirements and other factors.
In short, its manufacturing operation is
in constant flux. With EnerNOC for DR,
Vapor Tech retains the ability to respond
to DR events based on current conditions.
“EnerNOC lets us decide what to shut down
depending on the day and workload,” says
Vapor Tech’s manufacturing facility includes
large motors, vacuum pumps, heaters, and
other energy-intensive systems. “Energy is
definitely one of our largest expenses. So we’re
always looking for ways to lower our energy
costs,” says Eric Sprague, operations manager.
In general, efficient manufacturing relies
on keeping production moving ahead at all
times. However, Sprague and other Vapor
Tech leaders knew that there was flexibility
in the manufacturing operations that would
allow for temporary shutdown of some of its
nine PVD systems and related equipment.
“We knew we couldn’t shut down our whole
© 2010 EnerNOC, Inc.
With EnerNOC, Vapor Tech is able to reduce energy consumption
and improve the efficiency of its production operation.
Manufacturing
With DemandSMART, we know
more about how we’re using
energy. So we can continue to
improve, reduce, and save.
Eric Sprague, Operations Manager
Sprague. “But there are always areas where
we can reduce energy use.”
During a demand response event, Sprague
and other managers receive notification
from EnerNOC via email and phone. They
evaluate current conditions, then follow the
energy reduction plan to shut down systems
manually. PVD systems require as much
as one hour to shut down completely, so
Sprague and his team move quickly to make
changes on the manufacturing floor, shipping
and receiving area, labs, and front offices.
These changes are temporary, lasting a
maximum of four hours during a specific,
limited timeframe (9:00 AM to 8:00 PM). So
DR events do not affect Vapor Tech’s overall
production goals. “We can redistribute work
to other areas or shifts without any impact
on the company,” says Sprague.
Vapor Tech employees know about the
company’s participation in demand response,
and are supportive of it. “They know that
demand response is the right thing for our
company to do,” says Sprague. “It earns
money for us, and also helps protects the
company and the community from power
outages.”
The Results
Temporary changes to its production
operation enable Vapor Tech to reduce
its energy use by 200 kilowatts, earning
annual payments of approximately $5,000
from EnerNOC. These funds go directly to
the company’s general operating budget,
helping bolster the company’s bottom line in
challenging economic times.
Initially, Vapor Tech’s reduction goal was 150
kilowatts. However, during initial testing, it
What is Demand Response?
Demand response provides payments directly to organizations that choose to reduce
energy use during times of peak demand. EnerNOC DemandSMART is the industry’s most
comprehensive demand response application, allowing our customers to get the most
value from their participation in demand response programs throughout the US, Canada,
and the United Kingdom. EnerNOC works closely with customers to define customized
energy reduction strategies and ensure successful performance during events. EnerNOC
absorbs all costs and protects customers from any penalties that can be incurred for
not meeting reduction targets. Demand response helps stabilize your region’s energy
resources without requiring construction of new power plants—benefiting utilities, their
customers, and the environment.
became clear that the company could reduce
even more. In fact, during recent demand
response events, Vapor Tech delivered
energy reductions in excess of its 200 kW
target. Best of all, these changes happen
without any major disruption. “The whole
process has gone well,” says Sprague. “We’ve
gotten used to what we need to do for DR,
and it’s simply become part of the way
we work.”
The Benefits
Vapor Tech benefits from the muchappreciated payments it receives for
participating in demand response. But
equally important to the company is the fact
that DR is a good fit with the overall company
commitment to protecting the environment,
which starts with the company’s core
technology. Physical Vapor Deposition
is a much more ecologically friendly
method of coating metals than anodizing
or electroplating. This commitment to the
environment continues via a wide range
Want More Information?
Vapor Tech is just one of the many
innovative organizations that benefits
from EnerNOC’s comprehensive
energy management applications.
To find out more, call (866) 366-7820 or
visit www.enernoc.com/get-started.
Case Study | Vapor Technologies
EnerNOC lets us decide what to shut down depending
on the day and workload. But there are always areas
where we can reduce energy use.
Eric Sprague, Operations Manager
of other efforts. For example, Vapor Tech
is a member of the American Council on
Renewable Energy. And the commitment
is ongoing. “We’re always looking for new
ways to reduce energy consumption, and
to improve the efficiency of our production
operation,” says Sprague. EnerNOC brings a
range of powerful benefits to the company:
Free auditing and monitoring
During implementation, EnerNOC installed
free monitoring equipment and gave Vapor
Tech access to DemandSMART™, EnerNOC’s
comprehensive demand response application.
DemandSMART enables the company to
measure and monitor energy consumption,
and identify areas where it could reduce its
energy use. “I use DemandSMART during
events and also look at it every week,” says
Sprague. “In the past, we couldn’t know our
electric usage in real time. Now I know exactly
how much energy we’re consuming.”
Streamlined participation
Community support
EnerNOC made implementing DR a simple
process for Vapor Tech—from enrollment to
implementation to testing. “EnerNOC made
the whole process simple and smooth,” says
Sprague. “It’s all gone very well.”
By reducing its use of energy temporarily,
Vapor Tech can protect its company, and
the surrounding community, from power
outages and other issues. As a company that
relies heavily on a steady, reliable flow of
electricity, Vapor Tech is committed to doing
what it can to protect the local energy grid,
now and in the future.
A no-risk approach
Other DR providers impose penalties for
underperformance. Not EnerNOC. While Vapor
Tech is committed to achieving its target
reductions, it also has the flexibility to respond
to DR events based on current conditions in its
facility—without risk, and without penalties.
Responsive personnel
“We found EnerNOC extremely easy to work
with,” says Sprague. “If I had a question, they
were right there with an answer.” As the
ultimate vote of confidence, Sprague says
he would definitely recommend that other
manufacturing operations participate in DR
with EnerNOC if at all possible.
The Future
Working with EnerNOC and Xcel Energy, Vapor
Tech continues to look for new areas where
it can improve how the company uses and
manages energy. The knowledge gained from
DemandSMART aids these efforts to make
ongoing reductions by providing actual usage
data. “With DemandSMART, we know more
about how we’re using energy,” concludes
Sprague. “So we can continue to improve,
reduce, and save.”
EnerNOC, Inc. Headquarters
EnerNOC Ltd. Headquarters
EnerNOC UK Limited Headquarters
101 Federal Street
Suite 1100
Boston, MA 02110
Office: 617.224.9900
Fax: 617.224.9910
11-1155 North Service
Road West
Oakville, Ontario L6M 3E3
Office: 416.461.4678
Fax: 289.291.4001
Alder Castle, 4th Floor
10 Noble Street
London EC2V 7JX
Office: 0800.520.0303
Fax: (0)800.520.0192
EnerNOC, Inc. is headquartered in Boston, MA, United States, with wholly-owned subsidiaries in Canada (EnerNOC Ltd.) and the United Kingdom
(EnerNOC UK Limited). EnerNOC UK Limited is a company incorporated in England and Wales with company number 06937931, VAT number
GB980145422 and whose registered office is located at Alder Castle, 4th Floor, 10 Noble Street, London EC2V 7JX. A list of directors is available
for inspection at our offices.
© 2010 EnerNOC, Inc.
www.enernoc.com
For a full list of offices, please visit:
www.enernoc.com/about/contact.php
©2010 EnerNOC, Inc.
All rights reserved.
No text can be reprinted without permission.