Sara Lee: Improved Compressed Air System Increases Efficiency and Saves Energy at an Industrial Bakery

This case study was prepared for the Industrial Technologies Program of the U.S. Department of Energy (DOE); it describes the energy and costs savings resulting from improving the compressed air system of a large Sara Lee bakery in Sacramento, California. The compressed air system supports many operations of the bread-making machines, and it had been performing poorly. A specialist from DrawProfessional Services, a DOE Allied Partner, evaluated the system, and his suggestions included repairing a controller, fixing leaks, and replacing a compressor with a new one fitted with an energy-saving variable-speed drive. As a result, the bakery has reduced its energy use by 471,000 kilowatt-hours annually and is saving $50,000 per year in operating and maintenance costs.