Emsig Manufacturing Corporation (formerly US Button), founded in 1928 and managed by third and fourth generation family members, produces high-quality buttons that are distributed worldwide. The company’s facility in Putnam, Connecticut employs more than 80 people, and has approximately 90,000 square feet of space, including production areas, meeting spaces, and offices.

CHALLENGE

Emsig Manufacturing Corporation was looking to improve energy costs and equipment reliability without shutting down operations. After learning of Fidelity Energy & Sustainability’s expertise as a customer liaison to local energy providers, Emsig Manufacturing Corporation hired ESC to undertake major mechanical and lighting upgrades to an active manufacturing facility with approximately 60 employees operating five days per week in two shifts from 6:00 am to 11:15 pm.

SOLUTION

Despite the constraints of working in an active manufacturing facility, Fidelity Energy & Sustainability completed many energy efficiency upgrades. Highlights of the work included the design and installation of two dozen custom removable insulation jackets for steam system pipes and other components to prevent heat loss. Over 1,000 existing lighting fixtures were upgraded with efficient LED retrofits to brighten work spaces, and an old compressor was replaced with two compact, highly efficient compressors to reduce energy consumption and motor noise. An ultrasonic air study was performed to identify and repair air leaks.

RESULTS

The implemented measures were eligible for utility incentives and completed over a span of three months with no interruption to production. Emsig Manufacturing Corporation secured a $222,500 utility incentive to assist in the funding of their capital improvements. With these energy efficiency measures, Emsig Manufacturing Corporation decreased its annual utility costs by approximately 33%.

EXECUTED BY

Environmental Systems Co.

CLIENT

Emsig Manufacturing

CLIENT REFERENCE

Burt Elliott
Chief Operations Officer

SCOPE OF THE PROJECT

Steam System Insulation, Lighting Upgrades, Air Compressors, Boiler Conversion to Natural Gas, Steam Trap Survey and Replacement

PROJECT TYPE

Energy Solutions, Mechanical Services

PROJECT SIZE

Replaced 1,000 lights with LED, repaired 70 steam traps

BUILDING TYPE

Manufacturing

FES TEAM MEMBERS/ROLES

Jack Cunningham, Director Energy Solution Sales
Jamie Sykora, Energy Project Manager