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Better Plants Resources for Achieving Science Based Targets

The US Department of Energy’s (DOE’s) Better Buildings, Better Plants Program is a voluntary initiative that works with leading manufacturers to showcase leadership and drive deep energy savings in the U.S. industrial sector. Partners agree to set ambitious sustainability goals and in return receive robust technical assistance, national recognition, facilitated peer-to-peer learning opportunities, and access to innovation. Many Better Plants partners are looking to translate their energy intensity progress towards carbon reduction goals and exploring if setting a Science-Based Target (SBT) is right for their organization. This document provides an overview of the SBT initiative and compares it to the offerings of the Better Plants program. To help companies who are participating in both initiatives, DOE tools and resources are highlighted and discussed.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Better Plants Program Overview

The U.S. Department of Energy’s (DOE’s) Better Buildings, Better Plants Program is a voluntary partnership initiative to drive significant energy efficiency improvement across energy intensive companies and organizations. 157 leading manufacturers and public water and wastewater treatment utilities are partnering with DOE through Better Plants to improve energy efficiency, slash carbon emissions, and cut energy costs.

Partner Benefits, How to Join the Program↗

Energy Intensity Baselining & Tracking Summary Guide: Better Buildings, Better Plants

The Department of Energy (DOE) Better Plants (BP) program is a voluntary energy efficiency leadership initiative for U.S. manufacturers that encourages companies to reduce their energy intensity, typically by 25% within a ten-year period. BP partners are required to report their progress to the DOE annually by establishing an energy intensity baseline and tracking their energy consumption. BP partners receive access to a Technical Account Manager (TAM), DOE resources including software tools and trainings, and recognition when they achieve their goal. This summary guide provides the basics of baselining and tracking your energy intensity. For a more information and special considerations, please see the Energy Intensity Baselining and Tracking Guidance 2020.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

US DOE Better Plants Program Energy Treasure Hunt Exchange Toolkit

The US Department of Energy’s (DOE’s) Better Buildings, Better Plants Program works with manufacturing companies to improve their facilities’ energy efficiency. By partnering with the program, companies commit to long-term energy efficiency goals, typically 25% energy savings in 10 years. The program provides technical support to help partners obtain their goals and recognizes partners’ outstanding achievements. One of the technical support offerings from the program is the Energy Treasure Hunt Exchange In-Plant Training. The Treasure Hunt Exchange is an adaptation of the Kaizen methodology for energy efficiency originally developed by Toyota. DOE developed the Energy Treasure Hunt Exchange Toolkit to facilitate program partners’ execution of the energy treasure hunt processes. The toolkit covers three phases of an energy treasure hunt for all major energy systems: pump systems, fan systems, process heating systems, process cooling systems, steam systems, compressed air systems, lighting systems, and motor systems. All the tools included in the toolkit can be downloaded from the DOE website. The purpose of this report is to provide Better Plants partners an overview of the toolkit and detailed descriptions of its capabilities.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Workforce Development Opportunities Through the US Department of Energy’s Better Plants Program 2025

The increasing global demand for energy underscores the importance of energy efficiency and sustainability. To address these challenges in the US manufacturing sector, the US Department of Energy has implemented the Better Plants and Better Climate Challenge programs. These initiatives aim to reduce energy consumption, greenhouse gas emissions, and water usage in industrial facilities. This paper highlights a critical component of these programs, workforce development, which equips individuals with the skills and knowledge to implement energy-saving measures. Through the variety of training opportunities discussed, including bootcamps, in-plant trainings, virtual trainings, and annual events, the programs are able to cater to a wide range of industrial participants, from entry-level professionals to experienced engineers. By fostering collaboration and knowledge sharing and by leveraging certifications offered by organizations like the Association of Energy Engineers, these initiatives empower individuals to drive innovation and sustainable practices.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Better Plants: Progress Update Fall 2013

This Progress Update summarizes the significant energy saving achievements and cumulative cost savings made by these industry leaders from 2010-2012. The update also shares the plans and priorities over the next year for the Better Plants Program to continue to advance energy efficiency in the industrial sector.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Key insights from US Department of Energy Better Plants workforce development bootcamps (2022–2025)

This study examines the effectiveness of the US Department of Energy’s Better Plants Program Bootcamps, which are designed to enhance participants’ technical skills in improving energy efficiency and optimizing operations in manufacturing facilities. Through the analysis of survey data collected from 529 participants across 9 bootcamps, the research investigates the motivations, benefits, and demographic trends of attendees. The findings reveal that skill acquisition and improvement are primary drivers for participation, with key benefits including hands-on training on diagnostic equipment and software tools, networking opportunities, and access to technical resources. The analysis shows strong participation from sectors characterized by high energy consumption and employment, such as chemical and transportation equipment manufacturing. Over 50% of participants have job titles that include “EHS” or “Energy” showing their key roles in leading energy efficiency and energy management efforts in manufacturing. Furthermore, the analysis highlights the distribution of participants across managerial, engineering, and technical roles, revealing a higher representation of managers and engineers. This observation suggests a need for targeted outreach to engage technicians, equipment operators, maintenance staff, and floor workers to ensure comprehensive workforce development. The post-bootcamp survey showed that the participants highly valued the opportunities for peer learning and idea exchange, and the benefits they gained from them. This research contributes to the advancement of manufacturing education by demonstrating the efficacy of specialized training in addressing critical industry challenges and fostering a more competent and empowered workforce.

Energy efficiency↗

Unlocking Manufacturing Sustainability: Energy Efficiency Opportunities through the US Department of Energy’s Better Plants Program Energy Treasure Hunts (2023–2024)

The US manufacturing sector faces critical challenges: improving sustainability, reducing energy consumption, and reducing greenhouse gas emissions. Energy Treasure Hunt (ETH) training, a service provided by the US Department of Energy’s Better Plants program, offers a compelling solution. Although ETHs have traditionally focused on energy and cost savings, data indicate that ETHs can be used to identify opportunities to reduce emissions and water use and to support a sustainable and circular operation. These 3-day on-site events engage employees in a collaborative search for operational and maintenance efficiency improvement opportunities. The success of ETHs lies in a comprehensive methodology. Each phase in an ETH uses various tools and resources to empower employees to identify practical solutions. This study presents data from 13 ETHs conducted between 2023 and 2024 across diverse manufacturing subsectors in the United States and demonstrates that the events can help create a pragmatic decarbonization pathway. Through the events, a total of 234 energy and emissions reduction opportunities were identified, and the potential impact is significant. Implementing the recommendations could translate to annual savings of 497,299 MMBtu of energy, 64,374 kgal of water, and 4.85 million tCO 2 e of emissions. The fiscal savings from the proposed recommendations translate into nearly $\$$5 million annually. This study identifies the opportunities by energy system type and by the specific actions recommended, while also analyzing the identified opportunities, presenting the most established sustainability recommendations. Case studies from participating partners are presented to further demonstrate that ETHs provide a practical and impactful approach to reducing energy consumption, emissions, and operating costs and promote a more sustainable future for the industrial sector.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Initial Findings from US Department of Energy’s Better Plants Virtual in-Plant Training on 50001 Ready

Manufacturing facilities use about 35% of the domestic energy in the United States every year. Implementing an effective energy management system (EnMS) is one of the most important approaches to improve energy efficiency. However, the implementation of EnMS is low for many countries (including the US) and even for energy-intensive sectors. The reasons for the low implementation rate of energy management systems had been investigated by multiple researchers, but very few studies have focused on the barriers and challenges of implementing ISO 50001-based energy management systems. To contribute to this understudied area, this paper discusses the implementation and outcomes of the first Better Plants 50001 Ready Virtual In-plant Training. This paper first provides an overview of 50001 Ready and the 50001 Ready Navigator Tool. Then, it provides details on this training event and its outcomes. Finally, it discusses findings from the responses to 40 live polling questions about the status of the 25 tasks of the 50001 Ready Navigator for participating companies, key components of the participating manufacturing companies’ energy management systems, and challenges and barriers that these companies are facing. The findings suggest that although many companies understood the importance of an effective energy management system, about half of them do not understand the required resources for building energy management systems, and most of them have only just begun establishing these systems and need more assistance and resources in multiple areas. More specifically, more assistance is necessary for the following: (1) improving corporate management’s understanding of the time and resources needed to build an EnMS as well as the benefits; (2) creating linear regression models for more accurate energy performance tracking; (3) understanding energy use, collecting and analyzing energy performance data; (4) optimizing equipment operational controls, and creating action plans.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

US Department of Energy Better Plants Program’s Approach to Manufacturing Workforce Development

Multiple studies suggest that by 2030, millions of jobs may go unfilled because of a significant skills gap between the current manufacturing workforce and the workforce needed to support the shift toward advanced and sustainable manufacturing. According to US manufacturers, finding the right talent is more difficult now than in previous years. Developing a well-trained workforce will play a critical role in transforming the manufacturing sector into a net-zero contributor of greenhouse gas emissions by 2050. To help reduce energy, water, waste, and greenhouse gas emissions as well as build a strong, sustainable manufacturing workforce, the US Department of Energy created the voluntary Better Plants program in 2011. This study discusses the program’s various workforce development activities, including in-plant trainings, virtual in-plant trainings, and in-person bootcamps. The target audiences, training objectives, and topics designed to upskill workers for a low-carbon manufacturing future are described. Feedback that was collected (e.g., new training topics, certifications, hands-on activities) while working with more than 270 US manufacturers for the past 12 years on workforce development are discussed. Finally, some strategies are proposed to address the feedback.

Guo, Wei↗

Better Plant Data at the Root of Ecosystem Models

Version 2 of the Fine-Root Ecology Database. Fine roots are complex and dynamic structures that serve many critical roles for land plants. Their well-known importance for acquiring water and nutrients and associations with soil microbes underpin many terrestrial processes, including the movement of carbon, nutrients, and water through terrestrial ecosystems. Despite this importance, uncertainty shrouds the traits and processes associated with these enigmatic organs. Such uncertainty limits confidence in our terrestrial biosphere models that incorporate information based on fine-root data. For example, without knowledge of how roots grow and function, scientists struggle to predict how plants and ecosystems will respond to changes in atmospheric carbon dioxide as belowground resources become more limiting to plant growth. To address this challenge, an international group of researchers developed and released in 2017 the first version of a new resource: the Fine-Root Ecology Database (FRED) [Iversen et al., 2017]. Since that time, FRED has undergone significant improvement and additions, culminating in the release of FRED version 2.0 [Iversen et al., 2018]. FRED is a fully open resource containing species-specific as well as mixed-species root trait data that encompass all vegetated terrestrial biomes.

54 ENVIRONMENTAL SCIENCES↗

Industrial Energy Management During a Pandemic: Lessons Learned from DOE Better Plants Program Partners

The COVID-19 pandemic is causing many challenges for manufacturers, especially those that depend on workers whose jobs cannot be performed remotely. This has detrimentally impacted the energy management workforce, energy support system performance, as well as operations and supply chains.This article discusses four primary challenges for industrial energy management caused by the pandemic, strained budget for energy projects, increased energy intensity caused by low production rates and other safety practices, limited access to energy systems, and the lost knowledge and experience of senior staff. This article also proposes some potential solutions for these challenges that include implementing no- and low-cost energy conservation measures, adopting alternative financing options, improving shutdown procedures, reducing baseloads, creating an effective online energy-monitoring system, performing virtual energy assessments, building a robust EnMS, and attending online and in-person training events.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Practices Implemented by DOE Better Plants Program Partners to Mitigate COVID-19

Screening for symptoms, maintaining physical distance, sanitizing surfaces, wearing appropriate face masks, maintaining good personal hygiene, and reconfiguring HVAC air management are the major activities that the DOE BP partners have implemented to mitigate COVID-19. This article shares some specific practices that BP program partners have implemented for these activities. The energy impact of some practices has also been discussed and some rules of thumb have been provided to estimate energy penalties.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Demand Response in Industrial Facilities: Peak Electric Demand

The US Department of Energy’s (DOE’s) Better Buildings, Better Plants Program (Better Plants) is a voluntary energy efficiency leadership initiative for US manufacturers and water/wastewater entities. The program encourages organizations to commit to reducing the energy intensity of their US operations over a 10-year period, typically by 25%. Companies joining Better Plants are recognized by DOE for their leadership in implementing energy efficiency practices and for reducing their energy intensity. Better Plants Partners are assigned to a Technical Account Manager, who can help companies establish energy intensity baselines, develop energy management plans, and identify key resources and incentives from DOE, other federal agencies, states, utilities, and other organizations that can enable them to reach their goals. Better Plants Partners are expected to report their progress to DOE once a year. This involves establishing an energy intensity baseline upon joining the program and then tracking their progress over time. Demand Response in Industrial Facilities: Peak Electrical Demand is intended to help companies understand peak demand response programs offering by their local utility. Manufacturing industries can learn about time-varying rates and smart technologies they can use to help them reduce their energy bills. This guidance document is applicable to companies participating at either the program or challenge level. Although this guide is intended primarily to assist companies participating in Better Plants, the methodologies and guidance within the document are applicable to any organization interested in understanding peak demand response programs.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Demand Response in Industrial Facilities: Peak Electric Demand

The US Department of Energy’s (DOE’s) Better Buildings, Better Plants Program (Better Plants) is a voluntary energy efficiency leadership initiative for US manufacturers and water/wastewater entities. The program encourages organizations to commit to reducing the energy intensity of their US operations over a 10-year period, typically by 25%. Companies joining Better Plants are recognized by DOE for their leadership in implementing energy efficiency practices and for reducing their energy intensity. Better Plants Partners are assigned to a Technical Account Manager, who can help companies establish energy intensity baselines, develop energy management plans, and identify key resources and incentives from DOE, other federal agencies, states, utilities, and other organizations that can enable them to reach their goals. Better Plants Partners are expected to report their progress to DOE once a year. This involves establishing an energy intensity baseline upon joining the program and then tracking their progress over time. Demand Response in Industrial Facilities: Peak Electrical Demand is intended to help companies understand peak demand response programs offering by their local utility. Manufacturing industries can learn about time-varying rates and smart technologies they can use to help them reduce their energy bills. This guidance document is applicable to companies participating at either the program or challenge level. Although this guide is intended primarily to assist companies participating in Better Plants, the methodologies and guidance within the document are applicable to any organization interested in understanding peak demand response programs.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Energy Intensity Baselining and Tracking Guidance

Each company joining the U.S. Department of Energy’s (DOE’s) Better Buildings, Better Plants Program (Better Plants) commits to establishing an energy consumption and energy intensity (EI) baseline and to tracking its energy performance over a 10-year period against that baseline. The baseline must reflect a company’s energy consumption over a 12-month period, covering all its U.S.-based operations. Energy consumption is calculated by fuel type in terms of primary energy (also known as source energy). EI is broadly defined as the amount of energy consumed per unit of output produced. For this guidance document and for the program, the term energy performance represents an evaluation of a facility’s capacity to use energy efficiently. Metrics used to assess a facility’s energy performance can include EI, energy consumption, improvements in EI, etc. Establishing an energy baseline and tracking system is a critical first step in effectively managing energy use. Developing a baseline can help a company understand energy use within the corporation and give it a point of comparison to evaluate future efforts to improve energy performance. It can also support efforts to validate a company’s energy management activities, improve comparative analyses when using benchmarks, and help in predicting future energy needs. In addition, a company that normalizes its performance data can determine highly defensible measures of energy savings generated through implemented energy efficiency projects. Establishing a baseline and tracking energy performance is also a requirement for ISO 50001 certification. Although basic energy data can be collected through utility bills, most manufacturers will have to perform additional analyses to develop accurate and robust energy baselines and tracking systems. Energy is consumed in many ways within the manufacturing sector and can come from multiple sources. Energy is sometimes generated and sold to other parties or captured and reused on-site. External events can exert a significant impact on a facility or company’s energy use independent of any purposeful efforts to improve energy efficiency. Operational changes, such as production shifts—which may be inevitable for some companies over the 10-year period covered by the program—can also make a big difference in energy use. Since Better Plants asks companies to account for all their U.S.-based operations, mergers, acquisitions, and divestitures can also have significant implications for a company’s energy metrics. This document aims to demystify the sometimes complex baselining process. It devotes special attention to the task of normalizing and adjusting energy consumption to account for external factors, such as weather and production changes. A key recommendation is that companies use regression analysis to normalize their energy consumption data whenever possible. Regression analysis is a statistical technique that estimates the dependence of a variable (i.e., energy use in the context of Better Plants) on one or more independent variables such as ambient temperature, while controlling for the influence of other variables at the same time. A properly developed regression analysis can provide a reliable estimate of energy savings resulting from energy improvement strategies and projects by accounting for the effects of variables such as annual production levels and weather. DOE has developed a companion Energy Performance Indicator software tool (EnPI) to simplify the baselining process. This tool can run regression models, calculate changes in EI at the facility level, and automatically compile facility-level data into a corporate-wide metric. Note that although the relevant equations used to calculate EI are provided in this document, the EnPI tool will automatically perform most calculations for the user. Additionally, Better Plants Partners (Partners) can call on their Technical Account Manager (TAM) to help them establish a baseline and assist with the necessary calculations to track progress.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

US DOE In-Plant Trainings to Develop Expertise and Replicate Success

In-Plant Trainings (INPLTs) offered by the US Department of Energy Better Buildings, Better Plants (Better Plants) program are multi-day workshops performed by industry-recognized experts. INPLTs include both classroom- and field-based sessions that train attendees to identify energy conservation opportunities, quantify savings from these opportunities, and implement projects to realize the savings. These training workshops enhance the attendees’ understanding of working principles, knowledge of best practices, and capability to analyze the energy performance of industrial energy systems. INPLTs are competitively awarded and focus on a wide range of topics, including traditional industrial systems such as steam, process heating and motor-driven systems, and processes such as energy treasure hunts and municipal water and wastewater treatment. Partners that are awarded INPLTs can invite external stakeholders, such as employees of other manufacturers, utility representatives, and vendors. The Better Plants program had delivered 123 INPLTs as of spring 2019, trained more than 2,000 participants, and identified more than $37 million in energy cost savings. This paper provides an overview of INPLTs, some key statistics, the top identified energy savings opportunities, and success stories from INPLTs delivered from 2011 to 2018. Finally, the vision for future INPLTs is discussed based on participants’ feedback and the long-term and strategic goals of the Better Plants program.

Guo, Wei↗

U.S. DOE’s Energy Treasure Hunt Exchange In-Plant Trainings – DOE Resources, Early Results and Lessons Learned

The primary objective of the Department of Energy’s (DOE) Energy Treasure Hunt In-Plant Training (INPLT) is to train Better Plants partner employees to lead and conduct future energy efficiency Treasure Hunts within their facilities without DOE assistance. By taking a “learning-by-doing” approach, this INPLT, like other DOE INPLT trainings, has the added benefit of uncovering real energy and cost-saving opportunities. This INPLT leverages DOE and Better Plants technical staff, resources and tools and the EPA “Energy Treasure Hunt Guide: Simple Steps to Finding Energy Savings” process. While Treasure Hunts are a relatively well-known approach to identifying energy-savings in manufacturing plants, DOE is adding several additional elements in its Treasure Hunt Exchanges. The first element is technical assistance and methodology. DOE provides high-quality technical resources, such as energy efficiency calculators, fact sheets, source books etc., to facilitate the Treasure Hunt process and teaches four fundamentals: 1) how to profile equipment, 2) how to collect data, and 3), data & ROI calculation methodologies. Another element is the “train the trainer” approach wherein the training facilitator will train at least one partner employee to facilitate future treasure hunts. Another element is that DOE provides energy diagnostic equipment and teaches the participants how to use them. Finally, DOE also offers partners the opportunity to exchange teams of employees either within a partners’ enterprise or with other partners to conduct the treasure hunt in each other’s facilities. This exchange of teams is important because each team can bring different insights and uncover energy-saving opportunities that would otherwise be missed. This paper will discuss DOE methodology and the early results and lessons learned from DOE’S Energy Treasure Hunt In-Plant Trainings at Better Plants Partner facilities.

Nimbalkar, Sachin U.↗