Edit Template
Edit Template

Success Stories: Proven Results in Energy Efficiency

Real-World Solutions. Massive Energy Savings.

At Blackhawk Equipment, we don’t just provide equipment; we deliver measurable financial results. Our engineering and audit teams have helped facilities across Colorado and beyond uncover hidden inefficiencies, stabilize production pressure, and secure some of the largest utility rebates in the region.

Explore the case studies below to see how our Professional Air Audits and System Designs translate into lower operational costs and increased profitability.

1. Metal Beverage Container Company – Colorado

The Challenge

A high-volume manufacturing plant was running seven 600 HP centrifugal compressors and one 1,000 HP unit. The equipment was aging, inefficient, and the controls were not synchronized, leading to massive energy waste. A previous project with another vendor had failed to yield any savings.

  • Conducted a comprehensive audit and developed a specialized Measurement and Verification plan to satisfy Xcel Energy’s “Self-Direct” program requirements.
  • Recommended replacing the entire aging fleet with a single, high-efficiency 1,750 HP compressor.
  • Energy Savings: Verified savings in excess of 931 kW (1,247 HP).
  • Utility Rebate: Blackhawk successfully secured a $684,000.00 cash rebate for the customer.

2. Momentum Recycling – Broomfield, CO

The Challenge

As a premier glass recycling facility, Momentum Recycling manages a complex, multi-stage industrial process. After a year of operation, they questioned their system’s performance and turned to Blackhawk for an optimization strategy.

  • Optimized Compression: Replaced a pair of 100 HP constant-speed machines with a single Sullair V250S-250L. This unit utilizes both Variable Speed Drive (VSD) and Variable Capacity Control to maintain peak efficiency even during part-load conditions.
  • Eliminated Waste: Installed a Blower Purge Desiccant Dryer, utilizing heated ambient air for regeneration instead of using costly compressed “purge air”.
  • Weekend Shutdown Strategy: Integrated a small reciprocating compressor specifically for the fire suppression system, allowing the large 100 HP main units to be shut down during non-production weekends.
  • Achieved significant energy savings and secured a major rebate through the Xcel Energy Rebate Program.

3. Garlock Pipeline Technologies (GPT)

The Challenge

GPT’s existing 30 HP fixed-speed system was out of capacity, causing erratic system pressure that hindered the manufacturing of piping flange gaskets.

  • VSD Upgrade: Installed a 50 HP Variable Speed Drive (VSD) compressor and a matching dryer to handle demand events and stabilize pressure.
  • Infrastructure Remediation: Replaced inefficient rubber hoses (which have 4x the pressure drop of hard pipe) with high-performance hard tubing.
  • Leak Management: Implemented a quarterly leak maintenance program to address polyurethane tubing failures.
  • Point-of-Use Optimization: Installed regulators on blowguns to limit pressure to 35 psig, which is sufficient for debris removal while minimizing air waste.
  • Project Payback: Achieved full ROI in just 2.93 years through energy savings.
  • Incentive: Secured an Xcel Energy Rebate of $6,137.

What Could Your Facility Save?

These success stories represent just a fraction of the millions of dollars we have saved our clients. Whether you need to stabilize erratic pressure or secure a massive rebate for a system overhaul, our DOE AirMaster+ Specialists are ready to help.

Keep Updated About Our Product

You have been successfully Subscribed! Ops! Something went wrong, please try again.
5295 Vivian Street, Arvada, CO 80002
Serving CO, WY, UT, NM, MT

Need emergency support? 303-975-8800
Hours:
“Mon-Fri: 7am – 5pm MST | 24/7 On-Call”

© 2026 Blackhawk Equipment. All Rights Reserved.