System Assessments
As the Best Practices Magazines celebrate their twentieth anniversary, we wanted to take a moment to reflect on the remarkable system efficiency gains achieved since our first issue. We also wanted to give subscribers a peek at what the next decades might bring. To do this, we asked a hand-selected list of original equipment manufacturers, independent compressed air system sales and service companies, manufacturing plants and independent system auditors to share their thoughts, highlighting the changes they’ve seen over the past 20 years, then predicting what the next 20 years will bring.
As the Best Practices Magazines celebrate their twentieth anniversary, we wanted to take a moment to reflect on the remarkable system efficiency gains achieved since our first issue. We also wanted to give subscribers a peek at what the next decades might bring. To do this, we asked a hand-selected list of original equipment manufacturers, independent compressed air system sales and service companies, manufacturing plants and independent system auditors to share their thoughts, highlighting the changes they’ve seen over the past 20 years, then predicting what the next 20 years will bring.
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Free cooling offers a highly efficient alternative to chiller-based cooling, but its success depends on effective operation and control—especially during system transitions. This article outlines practical techniques for improving the shift between chiller and free cooling modes, minimizing temperature spikes and maintaining process stability in industrial environments. It also covers strategies for enhancing chiller performance under low-temperature conditions, optimizing heat exchanger startup, setting reliable control triggers and addressing maintenance and freeze protection. With proper tuning and operation, facilities can significantly increase free cooling hours, reduce energy use and extend chiller life without risking production disruptions.
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This article details how Schneider Electric transformed waste heat into a reliable energy source at its Lincoln, Nebraska facility. By repurposing low-temperature process cooling water and optimizing building pressurization and controls, the plant significantly reduced natural gas use, water consumption and CO2 emissions while improving indoor comfort and air quality. The project demonstrates how an efficiency-first approach—leveraging existing infrastructure, advanced controls and digital analytics—can deliver measurable sustainability gains and create a scalable pathway toward full electrification and net-zero operations.
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Optimizing chiller lift is critical for improving energy efficiency, enabling heat recovery and meeting higher-temperature heat rejection demands in modern facilities. This article explain how advanced centrifugal compressor designs, variable speed drives and variable geometry diffusers enhance lift control while reducing power consumption. As heat pump applications and water constraints drive demand for higher lift performance, next-generation chiller technologies are redefining efficiency across commercial and industrial cooling systems.
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Pump systems account for a significant share of energy use in industrial, commercial and municipal facilities, yet many operate far from optimal performance. This article explains how pump system assessments identify hidden inefficiencies in pumps, controls, piping and operating strategies, often uncovering opportunities to reduce energy consumption by 20–50% while improving reliability. Through real-world examples and best practices, it shows why data-driven pump system optimization is essential for lowering total cost of ownership and achieving long-term sustainability goals.
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A building materials manufacturer solved persistent dust buildup by using a custom chiller designed to operate below the ambient dew point, intentionally creating condensation on process equipment. This case study shows how Delta T Systems integrated ambient dew point sensors and variable speed drive (VSD) technology to optimize chilled water temperature, reduce cleanup time, and improve energy efficiency. The solution delivered measurable maintenance savings and became a scalable model for process cooling and chiller optimization across multiple facilities.
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A building materials manufacturer solved persistent dust buildup by using a custom chiller designed to operate below the ambient dew point, intentionally creating condensation on process equipment. This case study shows how Delta T Systems integrated ambient dew point sensors and variable speed drive (VSD) technology to optimize chilled water temperature, reduce cleanup time, and improve energy efficiency. The solution delivered measurable maintenance savings and became a scalable model for process cooling and chiller optimization across multiple facilities.
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Advancements in heat pump chiller technology now enable efficient recovery of low-grade waste heat, expanding applicability beyond the temperature limitations of traditional absorption systems. When integrated with AI-driven CUP optimization platforms, these systems enhance thermal efficiency, stabilize process loads, and improve overall plant performance.
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How do you fundamentally transform the utility carbon make-up of a fully occupied, 53-story skyscraper without disrupting the high-profile tenants who depend on its seamless operation? The answer, it turned out, was not just to replace old equipment, but to completely reimagine how the building uses and reuses energy.
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Faced with the requirement for improved cooling, a blow molding plant chose to invest in a significant redesign of its cooling systems that combined two separate systems into a single, integrated system. The combined design leveraged the components to provide a more controlled, efficient system while also requiring less space than the alternative would have needed.
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