"Whatever keeps jobs in Cookeville, we want to explore the opportunities."

Rick Lineberry, plant manager at Cookeville's Tutco Inc., is clear on why the company recently took advantage of the no-cost energy assessment led by our university through the Tennessee 3-Star Industrial Assessment Center. As a manufacturer of heating elements, Tutco employs about 300 area workers.

"If we can do anything to make our plants more efficient, we want to do it because this is our community," he said.

Tutco recently opened its doors to our mechanical engineering students and a lead faculty member who spent the day assessing the plant's heating and air conditioning, lighting and air compressor systems. The goal was to find ways to save energy that would pay for themselves in two years or less.

Lineberry says although plant management conducted its own assessment of how efficiently power was being used, it made sense to call in the IAC at no cost to bring a fresh perspective to the study.

The visit brought to reality what the concept of the Tennessee 3-Star IAC was created to accomplish -- give the state's small- and medium-sized manufacturers a better chance to compete by helping them save money through energy savings. The center, led here with satellite offices at East Tennessee State University and the University of Memphis, is the only IAC funded in the state by the Department of Energy. Tutco received just the second assessment under the newly formed center.

"Participants receive a preliminary report the day of the assessment about the possibilities of what types of changes can be made with potential savings," says Glenn Cunningham, co-director. "We follow up with a full report in 60 days making recommendations for changes, listing estimated cost savings and simple payback.

"The program includes a six-month follow-up assessment of how changes were made and if they were successful in meeting the goals of saving energy and eliminating waste," Cunningham says.

Participants are required to provide personnel to assist the analysts and fill out a pre-survey.

The assessment began with an orientation meeting with plant managers and the assessment team. Analysts then spent a full day at Tutco's main Cookeville facility, often stopping to talk with maintenance supervisors who explained the workflow and how it affected power usage. The day ended with a summary meeting where the IAC team presented its preliminary findings and savings estimates.

"We were able to identify a potential for tens of thousands of dollars in savings, plus improved working conditions, through this assessment," said Cunningham. "This type of result can help manufacturers in the state keep their costs lower and help them afford to keep jobs in Tennessee.

"Another goal of the IAC is to train students in identifying potential industrial energy efficiency improvements," he added.

Small- to medium-sized manufacturers, defined by the DOE as those with annual energy costs between $100,000 and $2.5 million, can apply for assessment by contacting Ken Currie at 931-372-3836.