Optimizing Energy Efficiency, Enhancing Performance
Founded in 1998, Productive Energy Solutions, LLC is a Madison, Wisconsin-based mechanical engineering consultancy specializing in the optimization of industrial fan, pump, and motor systems. Led by expert engineer Ron Wroblewski, PE, the practice has identified more than $50 million in potential annual energy savings across 150+ industrial facilities globally. It delivers specialized training and consulting services to manufacturers, utilities, and government organizations worldwide, helping facilities improve energy efficiency, enhance production, and reduce operational costs.
Ron WroblewskiPrincipal Engineer & Founder
Flexible online courses covering fan, pump, and motor system optimization delivered via live webcasts and self-paced learning modules in partnership with AMCA International.
Interactive virtual sessions combining live instruction with real-world applications.
Flexible independent learning pathways managed via the AMCA online Learning Management System.
Multi-level curriculum spanning basic principles, fan types and selection, troubleshooting, performance curves, and advanced diagnostics.
In-person, hands-on training for technical teams and utility clients, ranging from short introductory sessions to multi-day intensive programs delivered globally.
Targeted introductory courses covering motors, VFDs, fan and pump optimization, and HVAC systems.
Customized technical courses tailored to the specific mechanical equipment and experience levels of manufacturing teams.
Intensive multi-day training programs focusing on practical measurement, in-situ testing, and advanced system optimization.
Technical engineering consulting for industrial systems, providing detailed energy assessments, in-situ measurements, system design, and specialized troubleshooting.
Thorough field testing and system diagnostics to identify optimization opportunities and operational improvements.
On-site fan and pump testing utilizing specialized diagnostic tools like Pitot tubes and strobe tachometers.
Addressing system inefficiencies, insufficient airflow, vibration, reliability concerns, and equipment failures.
Analysis of motor-driven systems and variable frequency drive applications to maximize energy savings and reliability.
Aggregates & Quarrying · Manufacturing · Metals · Pulp & Paper · Mining · Wood Products · Semiconductors · Utilities
Burns Harbor, Indiana · Metals · Client: ArcelorMittal
Identified short-term, measurable energy upgrades at the Burns Harbor steel mill to achieve $527,000 per year in potential savings, and resolved an operational issue on a 1,000 hp combustion-air fan to quickly restore critical boiler operations.
California · Manufacturing · Client: Holcim Cement
Uncovered multiple areas for energy optimization and operating cost reduction across various facility systems, identifying potential savings of $735,000 annually and an additional $3.3 million across medium-to-long term project horizons.
British Columbia, Canada · Mining
Conducted an intensive on-site evaluation of high-pressure blower and mechanical systems at a remote mine-mouth processing plant, identifying key efficiency measures to save over 10 million kWh per year, translating to $500,000 in annual cost reductions.
Southern Illinois · Manufacturing
Diagnosed poor fan performance as the root cause of insufficient airflow in a paint-facility exhaust system, providing the technical basis for the client to direct their mechanical contractor to restore correct process ventilation.