New Balance Athletic Shoe (China) Inc.

At a Glance

Industry

Industrial Goods and Manufacturing

Project Type

Industrial Energy Efficiency

Year

2017

Location

Yichun, China

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Net Present Value:

$140,000

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Annual kWh Savings:

310,000 kWh

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Annual CO2 Reductions:

170 metric tons

Summary

Sheng Cao researched and designed a smart energy metering system and identified energy efficiency improvements for one of New Balance’s footwear suppliers, CJ2.

Goals 

New Balance is helping its suppliers to improve energy efficiency and reduce emissions associated with their manufacturing activities. As a returning EDF Climate Corps participant, CJ2 already set an energy efficiency plan and has been implementing energy conservation projects. Looking to dig deeper and gain a better understanding of their energy use, CJ2 enlisted EDF Climate Corps fellow Sheng Cao to research, design, and implement a smart energy metering system that would allow greater visibility into how and where energy is being used within the factory. Secondly, Cao also helped the factory to identify additional energy saving opportunities associated with some of their key systems.

Solutions

After gaining an understanding of the energy supply and distribution system at CJ2, Cao designed a two-part smart metering plan. Cao researched technology vendors and worked with CJ2 management to decide on a final selection based on flexibility, cost, software features, data transmission, and local tech support capabilities. The implementation plan was vetted by the external vendor, and an onsite energy investigation was done to ensure that the system could be applied at CJ2.

 Cao soon realized that CJ2 lacked the internal methodologies and tools needed to analyze energy use data generated by the system. To overcome this, Cao designed an Excel-based energy statistics and analysis template for CJ2 to better manage energy data and find energy-saving opportunities, and then trained the factory team on how to use the system after installation.

While researching key energy systems within the metering plan, Cao also audited CJ2’s air compressor system and high power electric motors. He recommended three implementable energy efficiency projects, including compressed air leaks repair, exhaust motor adjustment and electromagnetic valve adjustment.

Potential Impact

Over their lifetime, Sheng’s air compressor and motor recommendations could save CJ2 ¥923,719 in net present value. Annually, CJ2 could save 313,800 kWh of electricity and reduce 164.96 metric tons of carbon dioxide emissions. With the smart metering system and the energy data analysis tool, CJ2 can better understand its energy consumption situation and identify more energy-saving opportunities in the future.


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