UConn Helps Manufacturers Cut Energy Costs, Boost Efficiency

As part of Shipman & Goodwin’s Manufacturing Month series, manufacturing attorney Alfredo Fernández spoke with Dr. Liang Zhang, Director of UConn’s Southern New England Industrial Training and Assessment Center, about the U.S. Department of Energy–funded program helping manufacturers across Connecticut improve energy efficiency, cut costs, and strengthen sustainability.

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For more than four decades, the U.S. Department of Energy’s ITACs across the country have supported small and mid-sized manufacturers by providing on-site evaluations and recommendations to reduce energy use and improve productivity—all at no cost to the company.

At the University of Connecticut, the ITAC team serves facilities across Connecticut, New England, Long Island and New York City areas, helping manufacturers identify practical, high-impact ways to save energy and money.

“Our mission is to help manufacturers operate more efficiently and sustainably,” said Zhang.

“We focus on the systems that often get overlooked—compressed air, pumps, motors, HVAC, and lighting.

“These are the backbone of production, but they can also be the biggest sources of energy waste if they’re not optimized.”

Evaluation Process

When a manufacturer reaches out to ITAC, the process begins with an introductory call to learn about the facility’s operations, size, and energy profile.

From there, a team of UConn engineering faculty and students conduct a one-day on-site assessment to gather data on equipment, controls, and usage patterns.

“We bring meters and sensors to collect data right from the floor,” Zhang explained.

“Afterward, our team analyzes the results and produces a detailed report that outlines recommended improvements, estimated costs, energy savings, and payback periods.”

The recommendations often range from simple behavioral changes—such as fixing compressed air leaks or upgrading to LED lighting—to more strategic capital investments like variable-speed drives, improved insulation, or heat recovery systems.

“We tailor every report to what’s realistic for that company,” said Zhang. “Some actions pay for themselves in just a few months.”

High Value for Small Businesses

Fernández noted how valuable this resource is for smaller manufacturers that may not have dedicated sustainability or facilities teams. Zhang agreed.

“That’s exactly who this program was designed for,” he said.

“Many of these companies are laser-focused on production, so energy optimization falls off the radar.

“We help them see where improvements can translate into real dollars saved.”

The benefits go beyond individual companies. Each assessment doubles as a hands-on learning opportunity for UConn students studying engineering and energy systems.

“Students get to see how theory applies in real-world manufacturing settings,” Zhang said.

“It’s a powerful experience—students leave with skills that make them immediately valuable in the workforce.”

Long-Term Impact

Over time, the impact adds up.

Since its inception, UConn ITAC has conducted over 60 assessments, accumulating over 500 recommendations, and helping manufacturers collectively save millions of dollars in energy costs while reducing emissions and waste.

“It’s rewarding to see local companies become more competitive while advancing sustainability goals,” Zhang added.

According to Fernández, ITAC represents a unique collaboration between academia, government, and industry—one that directly benefits Connecticut’s manufacturing base.

“It’s an example of how innovation and partnership can drive practical, measurable results,” he said.

Fernández noted that the CTSMARTE program automatically includes an ITAC energy assessment and pairs it with other modern technologies, such high-performance computing-based modeling and simulation projects.

This article first appeared on CBIA's website and is published here with permission.