Energy Efficiency Audit of Energizer’s Battery Manufacturing Facility Asheboro, North Carolina

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2023-04-25

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Abstract

A team of Nicholas School of the Environment Master of Environmental Management (MEM) students were assigned to perform an energy efficiency audit at Energizer Holdings, Inc. (Energizer), Asheboro 2 Battery Manufacturing Facility located at 419 Art Bryan Drive, Asheboro, NC. The purpose of this master's project was to identify opportunities for energy savings, to identify high ROI (return on Investment) opportunities and contribute to Energizer’s climate and energy goals by conducting this energy efficiency audit. These goals include reducing greenhouse gas (GHG) emissions companywide by 30% by 2030. The energy savings will lead to the GHG reductions and serve as a pilot for Energizer to improve the energy efficiency of all its domestic and international facilities. This energy audit was created by using Level 1 and 2 energy audit guidelines provided by the American Society of Heating, Refrigerating, and Air-Conditioning Engineers (ASHRAE). We visited the facility multiple times to gather enough data to complete a bottom-up model of the facility’s energy consumption. This bottom-up model aggregated the motor type, voltage, current, and horsepower of each of the motors or appliances in various areas across the Asheboro 2 Plant. The team used the model to estimate energy usage from major load sources. All the data was collected by using Energizer’s Metrio system, Leaning2Lean smart manufacturing platform, physically counting lights, and estimating energy consumption from lighting and HVAC (Heating, Ventilating, and Air Conditioning). The team was not able to determine which motors should be replaced due to the motor analysis being outside of the scope of this project, as we do not have the expertise for this type of assessment. We recommend that Energizer conducts a formal observation on non- frequent usage appliances to determine if it’s necessary to maintain any redundant appliances. From our bottom-up model analysis we decided on the following recommendations that fulfill the purpose of the project for the facility:

 Convert the remaining portion of the facility to LED lighting.  Implement lighting sensors in the warehouse and storage rooms.  Conduct a separate further analysis of rooftop solar panel installation.  Replace exterior windows with a minimum of double pane windows.

We were able to perform an analysis that indicates energy savings, GHG emissions savings within Scope 1 and 2, upfront cost, net present value (NPV) of project investments, payback period, and long-term savings. Energizer can save 50-90% of the warehouses energy usage by replacing all remainder fluorescent light with LED lighting. This includes setting up 50 lighting sensors in the warehouse and storage room. The team considered an opportunity for Energizer to implement solar panels and net metering. By installing a 1000 kW solar system, there’s a potential of saving around $77,335-$110,333.3 USD per year. However, a further feasibility study and cost analysis must be conducted to justify the viability. Our last recommendation is to replace the windowpane glass with double pane glass because it will reduce heating and cooling costs by 44%. Each recommendation above is a project opportunity for Energizer to consider taking to meet their energy and climate goals.

As a team, we recommend that Energizer Holdings, Inc., implement the four project options that are found in the table below. These opportunities will reduce GHG emissions by 1.5 lbs. of CO2, which results in energy savings of around 1.9-2.2 million kWh per year, thus leading to saving about $167,432 per year. All the recommendations could be applied to their other facilities nationwide, unless otherwise noted.

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Buskard, Delaney, Yinan Ding, Jack McCabe and Jennifer Ronderos (2023). Energy Efficiency Audit of Energizer’s Battery Manufacturing Facility Asheboro, North Carolina. Master's project, Duke University. Retrieved from https://hdl.handle.net/10161/27101.


Dukes student scholarship is made available to the public using a Creative Commons Attribution / Non-commercial / No derivative (CC-BY-NC-ND) license.