Powerful Control, Proven Savings

About Bay Controls

At Bay Controls, our energy solutions are built on 30-plus years of experience and R&D in the industrial controls and integration market. Since 1983, Bay Controls has provided industry-leading compressed air controls and integration and automation solutions to a wide variety of customers in the United States and over 60 countries around the world. We provide cost savings for our customers through intelligent control strategies, improved system management, and increased reliability

Whether they are an automotive plant in Detroit, a textile mill in Turkey, or a copper mine in Chile, our customers rely on Bay Controls because we consistently deliver energy-saving solutions tailored to their unique needs. We don’t do one-size- fits-all. We do what works for you.

Bay Controls’ corporate headquarters and R&D center is located in Maumee, Ohio. We also have regional offices in Seattle, Washington, Tallahassee, Florida, and Monterrey, Mexico. In addition, our products are sold and supported by a large network of distributors in North America and internationally.

Products and Services

At Bay, we know what works. All of our controls, monitoring, integration, and automation solutions come with more than 30 years of industry experience and expertise built into them. We’re always looking to see what we can do better in the future. As a result, we continuously improve our products, so you can be confident our products and services are both state-of-the-art and backed by a track record of proven performance and reliability.

For detailed information regarding our products and services, please click below to learn more or contact us today.

Learn More...

Tailored Solutions

At Bay, we approach each project as a savings opportunity. Whether we’re working with compressors, chillers, cooling towers, HVAC, or other plant systems, our main focus is on saving customers money, energy, and time.

In the more than 30 years that we’ve been in business, Bay has helped industrial customers in 70 countries take advantage of savings opportunities. To date, Bay has installed 5000+ controls and solutions that save customers 1.8 Terawatt-hours (1,800,000 Megawatt-hours) annually. Some individual examples of the savings opportunities that Bay has helped its customers realize can be seen below.

Contact Us to discuss how Bay Solutions can work for you.

Case Studies

Ford Motor Company

Business: Automotive Manufacturing

Bay upgrades control hardware and improves compressed air systems at Ford resulting in annual savings of $3 million

Project Scope

Ford and Bay Controls implemented a state-of-the-art compressor control system for Ford's Vehicle Operations plants (22 facilities and 157 air compressors). Air compressors at each site were upgraded with the Bay Compressor Controller and integrated using distributed capacity control technology. In addition to the controls standardization, the project included internet-based monitoring of all air compressors via Bay's BayWatch service.

Project Summary

By utilizing the Bay Controls air compressor control system, each plant was able to optimize their compressed air requirements relative to energy use. The internet-based BayWatch monitoring system provides Ford with continuous real-time and historic air compressor performance information. Additional benefits included in this project were Bay Controls' auto start/stop, performance log, and scheduling software. This project included all engineering, labor, and training for a turnkey installation.

Energy Savings

Projected annual energy cost savings is $3 million (50,779,601 kWh) or a 13% improvement.

Project Cost

Total project cost was $3,654,710.

Payback

The payback period for this project was 15 months.

Other Benefits

Productivity, reliability, and maintenance benefits were realized with this project as well as energy savings.

Monitoring and Verifying Energy Savings

The BayWatch service was employed to monitor and verify energy savings.

Norfolk Naval Shipyard

Business: Shipbuilding

Bay creates a facility-wide billing systems for steam and water metering.

Project Scope

Bay Controls designed and implemented a state-of-the-art metering system for the Norfolk Naval shipyard (1275 Acres, 5.2 sq. km.). Facility personnel needed a way to take meter readings for steam and water usage at many locations throughout the facility from one, centralized location.

Project Summary

Bay Controls created a data acquisition framework that allowed the facility to use their existing Steam Flow meters while installing new water metering devices. Each device was connected to data acquisition controllers, which were then interconnected using a dedicated and secure fiber optic backbone throughout the facility. The entire system was integrated into a SCADA system that can be used by various departments and personnel to perform their job duties.

Project Benefits

Personnel are able to perform their job duties more efficiently without having to travel throughout the large, secure facility.

Project Cost

Total project cost was $650,000

Other Benefits

Productivity, reliability, and maintenance benefits were also realized with this project. A SCADA system was also put in place that was later expanded to include many additional systems that leveraged the communication and data collection capabilities that were put in place.

Southeastern Container

Business: Bottle Manufacturing

Bay Conducts Study to Identify Energy Savings Opportunities - Designs Plant-Wide SCADA System to Recognize Future Savings Potential.

Project Scope

With future energy savings in mind, Southeastern Container and Bay Controls created a procedure to log data and collect information. From the data, Bay would develop a comprehensive report to identify new energy savings opportunities.

Project Summary

Using portable metering devices along with BSI (Bay System Integrator) modules and a BayView Server system, Bay Controls was able to gather data for production and non-production periods for all major energy users. Bay Controls also worked with the plant personnel to observe how many of the system components were being utilized and operated. By combining these elements, Bay Controls was able to create a detailed project proposal for several key areas of energy savings opportunities.

Energy Savings

  • Power Factors Correction Savings Estimate - $69,500 annually
  • Booster Compressors Savings Estimate - $29,700 annually
  • Lighting Savings Estimate- $12,500 annually
  • Reciprocating Air Compressor Controls Savings Estimate - $18,000 / annually
  • HVAC Controls Savings Estimate – Numerous man hours for plant personnel due to centralized control.

Project Cost

Project Cost: $10,000.

Other Benefits

Plant personnel more readily recognize the key factors of energy savings as well as identifyingy, detailing, and reporting on each opportunity.

Monitoring and Verifying Energy Savings

The BSI (Bay System Integrator) and BayView Server were used to monitor and log energy usage.

Milliken

Business: Textile Manufacturing

Bay Upgrades Control Hardware and Improves Compressed Air Systems at Nine Milliken & Company Plants Allowing for Centralized Engineering Support.

Project Scope

Bay Controls implemented a state-of-the-art compressor control system for Milliken textile plants (38 air compressors across nine facilities). Air compressors at each site were upgraded with the Bay Controls Air Compressor Controller and integrated using distributed capacity control technology. In addition to the controls standardization, the project included internet-based monitoring of all air compressors via Bay's BayWatch service allowing both Milliken and Bay Controls air specialists to remotely assist each plant.

Project Summary

By utilizing the Bay Controls air compressor control system, each plant was able to optimize their compressed air requirements relative to energy use. The internet-based BayWatch monitoring system provides Milliken Container with continuous real-time and historic air compressor performance information. Bay was able to achieve a 1-2 psi pressure control window at all plants which allowed the plants to run fewer units thus saving energy. Additional benefits included in this project were Bay Controls' auto start/stop, performance log, and scheduling software. This project included all engineering, labor, and training for a turnkey installation.

Energy Savings

Projected annual energy savings: 11 percent.

Project Cost

Total project cost: $725,000.

Payback

Payback period for this project: 20 months.

Other Benefits

In addition to energy savings, upgraded facilities experienced improved productivity, and reliability, with fewer maintenance concerns.

Monitoring and Verifying Energy Savings

The BayWatch service was employed to monitor and verify energy savings.

Contact Bay

Bay Controls headquarters is located in Maumee, Ohio, a suburb of Toledo. To contact us feel free to phone, fax, e-mail, send a letter or simply visit our office. Our office hours are Monday through Friday, 8:00 a.m. to noon, and 1:00 p.m. to 5:00 p.m. Eastern Standard time.

We look forward to hearing from you!

Bay World Headquarters

Bay Controls, LLC.
6528 Weatherfield Ct.
Maumee, OH 43537-9468
Email: sales@baycontrols.com
Phone: 419-891-4390   Toll Free: 1-800-837-2292
Fax: 419-891-4399
After hours Emergency: 419-726-5669

Bay Latin American Headquarters

Ave. Eugenio Garza Sada 3720
Col. Villa Los Pinos
Plaza Regia, local B5
Monterrey, Nuevo Leon, Mexico CP 64770
Email: sales-mexico@baycontrols.com
Office: +52 (81) 8365-4744   Sales: +52 (81) 8365-4090
Fax: +52 (81) 8365-4744

West Coast Sales

Seattle, WA
Stephen Parry
Phone: 419-346-3162
Email: sales-west@baycontrols.com

Southeast Sales

Tallahassee, FL
Amy Otis
Phone: 419-891-4390 ext. 125
Email: sales-southeast@baycontrols.com

Bay Energy Partners

Bay Energy Partners, LLC is the energy-project-financing affiliate of Bay Controls. Bay Energy Partners was formed as a way to offer Bay Controls and BAYweb customers the ability to reduce their energy costs with no capital outlays. Bay Energy Partners is guided by the expertise and experience of the Bay Controls team and built on a philosophy of offering customers proven energy solutions that are backed by 30-plus years of industry experience.

How it Works

Under a typical Bay Energy Partners agreement, Bay Controls works with our customer to put together a tailored package of energy-efficiency upgrades (compressor controls, integration, automation, lighting controls, HVAC controls, etc.) that will result in the largest energy and cost savings. A portion of the cost savings from the project upgrades are then used to “pay” for the project over a period that can range from one to five years. During this period, the customer only pays a monthly installment that is agreed upon with Bay Energy Partners and is less than their monthly energy bill before the completion of the project.

At the end of the contract period, the customer owns all of the equipment from the project and continues to benefit from the cost savings for the life of the equipment.

Working With Bay Energy Partners

If you are interested in working with Bay Energy Partners to implement an energy-efficiency project using Bay Controls or BAYweb equipment, please contact our project team at energypartners@baycontrols.com or give us a call at 419-891-4390.

Bay Controls has provided energy saving solutions for over 30 years. We have a history of partnering with industry-leading companies to provide best-in-class energy-saving solutions. We have worked with many partners and solution providers over the years to create Air Compressor, Cooling Tower, Dryer and other control solutions to maximize energy savings for our customers

We are always interested in working with quality partners. Whether you need Bay to develop an OEM solution for your company, or you are looking to become a distributor of our products, we want to work with you. Please feel free to contact us if you would like additional information.

You see a compressor.

We see a chance to
boost your bottom line.

You see a problem.

We see potential.