National Gypsum has invested significantly in capital improvements to reduce energy usage.
The return on that investment has been a $2 million annual savings since 2004.
Most of the savings has come by upgrading board dryers with energy optimization systems. These systems use exhaust air from the first zone in the board dryer to preheat the air in zones two and three, saving tens of thousands of mm Btu's.
An energy coordinator at each location has the responsibility for finding ways to reduce energy use. In addition to the work at board dryers, the company has upgraded air compressor systems and modernized lighting to reduce costs.
The company uses infrared camera technology to detect heat leaks at kilns and repair them. This same technology is used to check motors and drives. In some cases, replacing worn drive systems has saved thousands of dollars in energy costs and improved efficiency and quality.