Figure 4.2 shows the result of this energy reduction process used successfully on an
industrial dryer’s steam usage. The General Mills dryer improvement plan was developed
and executed. These improvement plans are holistic and include all four M’s (Man,
Machine, Material, and Method). In other words, the maintenance program, operation,
operator training, new equipment, and controls were all optimized for energy efficiency.
The steam meter for that individual unit operation (not the header meter) verified the
savings (Figure 4.2). A new energy baseline for this unit operation was established for
each product. Then the dryer’s usage was monitored and the focus was sustained, driving
almost $100,000 in savings.