American Water Heater Company: Compressed Air System Optimization Project Saves Energy and Improves Production at Water Heater Plant

In 2001, American Water Heater Company implemented a system-level improvement project on the compressed air system that serves its manufacturing plant in Johnson City, Tennessee. The plant now operates with less compressor capacity, which has reduced its energy consumption and maintenance needs. The project's total cost was $228,000. The annual compressed air energy savings (2,345,000 kWh) andmaintenance savings total $160,000, yielding a simple payback of 17 months. Furthermore, the system now supports the plant's production processes more effectively, which has improved product quality and increased production.