Monadnock Paper Mills

Heat Recovery Cuts Propane Heating Bill 80%

ISO9001 Certified

Heat Recovery Cuts Propane Heating Bill 


"Propane purchases represented one of our largest energy costs last winter," says Keith Hayward, managing director of Monadnock Non-Wovens LLC in Mount Pocono. However, following the completion of a new heat recovery system, Monadnock now uses propane only to fuel forklift trucks and to power emergency systems in the event of electrical failure. "We are all pleased with the significant reduction in our propane costs and the corresponding reduction in the production of greenhouse gases," continues Hayward. "We have more than enough heat for even the coldest nights – and it costs us nothing more, as we simply reuse heat previously exhausted."

Using a series of fans, ductwork and control baffles, excess heat is reintroduced into the mill in cold weather and extracted in hot weather. This reduces severe temperature changes in the mill, stops cold drafts and reduces overall propane use by over 80%  even while heating a newly constructed factory building extension. This is being accomplished with the use of essentially free energy that has already been used in production. The project was completed at the end of 2010, just in time for the coldest period of the year, and has proved very effective.

Monadnock Non-Wovens of Mount Pocono, PA, produces polypropylene non-woven roll goods for use in facemasks, liquid and air filters, vacuum bags and a number of other applications for high-quality meltblown non-wovens. Plastic resin is melted in the production machinery, and each machine exhausts air carrying approximately 1 million Btu/hour of heat. The heat must be exhausted to control temperature buildup that could affect the processing conditions. Formerly, atmospheric makeup air was introduced untreated into the building directly from outside. Mount Pocono is a ski resort and experiences a long, cold winter with ambient temperatures in the region of 10 to 20 degrees Fahrenheit (-12 to -7 degrees Celsius). This frigid outside air was partially heated using propane to avoid some parts of the mill becoming too cold. While the new factory-wide air temperature control system still involves exhausting excess heat, some heat is retained when it is needed to provide comfortable temperatures for working even on the coldest winter nights. Heat is retained and regulated through ductwork and fans that are both economical and environmentally friendly. Monadnock Non-Wovens’ new system saves money and reduces the factory’s carbon footprint