image: The University of Texas at Arlington-based Texas Manufacturing Assistance Center, known as TMAC, is helping the state's manufacturers reduce pollution with real-time sensors that track their environmental impact. The innovative effort is producing results that could transform how companies protect air and water quality. The program recently earned TMAC an Environmental Excellence award from the Texas Commission on Environmental Quality issued by Governor Greg Abbott for technical innovation. “Our mission at TMAC is to help Texas businesses be more efficient and accelerate their growth, and that’s exactly what we did with this environmental program,” said TMAC Executive Director Rodney Reddic. “This also serves as a scalable model for manufacturers to help promote environmental leadership while improving manufacturing efficiency and reducing costs.”
Credit: UTA
The University of Texas at Arlington-based Texas Manufacturing Assistance Center, known as TMAC, is helping the state's manufacturers reduce pollution with real-time sensors that track their environmental impact. The innovative effort is producing results that could transform how companies protect air and water quality.
The program recently earned TMAC an Environmental Excellence award from the Texas Commission on Environmental Quality issued by Governor Greg Abbott for technical innovation.
“Our mission at TMAC is to help Texas businesses be more efficient and accelerate their growth, and that’s exactly what we did with this environmental program,” said TMAC Executive Director Rodney Reddic. “This also serves as a scalable model for manufacturers to help promote environmental leadership while improving manufacturing efficiency and reducing costs.”
Related: TMAC project aims to strengthen defense department supply chain
This is the first large-scale effort in Texas to use sensors for real-time pollution prevention. Building on its work with video systems to improve operations, TMAC tested a range of sensors that could measure energy use, water consumption, air quality, temperature and humidity. The goal was straightforward: measure current environmental conditions, recommend changes, then use sensors to track the results and document the improvements.
With one client, a fulfillment packager of snack protects, TMAC installed six sensors on packaging equipment. Data from a sensor measuring electricity use on an air compressor revealed significant energy waste—421,200 kWh a year—caused by air leaks, costing the client $39,171 annually. Fixing those leaks helped prevent 228 metric tons of carbon dioxide from being released. Encouraged by these savings, the client plans to expand the sensor technology to other Texas facilities, expecting to save $195,000 more.
Related: TMAC helping businesses prevent pollution
Working with an automobile parts supplier, TMAC used a flow sensor to monitor water use in the company’s automated washing chambers. The team detected excess water consumption and offered recommendations to reduce waste. Initial results are promising, with potential savings of nearly 3.5 million gallons of water annually.
TMAC also used an electric particulate sensor with a military parts manufacturer to detect air leaks that risked equipment failure and compromised product quality. Identifying these leaks could help the company save nearly $450,000 a year in operating costs.
“The success of any operational improvement and pollution prevention effort is only as good as the organization's ability to implement change and specific action steps to generate positive impacts,” said Kurt Middelkoop, TMAC sustainability advisor.
Middelkoop is the principal investigator on a grant from the U.S. Environmental Protection Agency that provided startup funds for the project.
“The accuracy of sensor data minimizes human error, offering leadership precise insights to evaluate the return on investment and environmental improvements,” Middelkoop added. “TMAC's sensor technology deployment not only helps companies reduce their environmental footprint, but it also ensures that Texas remains a leader in manufacturing and environmental stewardship, safeguarding our natural resources for future generations.”
About The University of Texas at Arlington (UTA)
Celebrating its 130th anniversary in 2025, The University of Texas at Arlington is a growing public research university in the heart of the thriving Dallas-Fort Worth metroplex. With a student body of over 41,000, UTA is the second-largest institution in the University of Texas System, offering more than 180 undergraduate and graduate degree programs. Recognized as a Carnegie R-1 university, UTA stands among the nation’s top 5% of institutions for research activity. UTA and its 280,000 alumni generate an annual economic impact of $28.8 billion for the state. The University has received the Innovation and Economic Prosperity designation from the Association of Public and Land Grant Universities and has earned recognition for its focus on student access and success, considered key drivers to economic growth and social progress for North Texas and beyond.