Intern: Jacob Hassan
Indiana University, Bloomington IN
The Alcan Packaging facility in Centralia produces plastic bottles using an injection blow mold
process. The facility employs 250 people, with 37 blow mold machines and 12 decorating
machines that run 24 hours, seven days a week. Alcan Packaging grossed over $12 billion in
2002 and operates facilities in 41 countries.
The intern conducted research on energy efficiency alternatives for the lighting, compressed air,
flame treatment and chiller/HVAC systems.
The intern recommended the following energy efficiency projects:
• Replace T-12 fluorescent light fixtures with T-8 fixtures. This project is estimated to
save $2,000 a year with a payback period just over 2 years.
• Repair air leaks in the four compressed air systems. This project is estimated to save
• Replace the mold core rod conditioning hoses in the compressed air systems. This could
save $4,800 annually in reduced energy expenditures. Additional compressed air savings
could be realized by replacing 31 air diverters with mechanical driven actuators. This
project could save $4,400 a year with a payback period of less than a year and one-half.
• Shut down the 300-ton chiller, which provides chilled water to air compressors, blow
mold machines and the air conditioning units on the plant floor. Install a geothermal
system to provide air conditioning and keep the other two chillers operating. Raise the
chilled water temperature to 50 degree F for the blow mold machines. Together, these
projects could save Alcan an estimated $79,000 a year in refrigeration costs.