In 2011, DPS began using third-party resources to get a more complete picture of our energy and water usage by site across our company. Over the ensuing year, the new processes have become embedded in our operations, and our manufacturing facilities are now able to more accurately and consistently report on consumption at each location.
With renewed confidence in our ability to track our utility usage over the past year and into the future, combined with the data we have collected since our spin-off in 2008, we now have the ability to understand the changes in our energy consumption over time and use the data in a more meaningful way to identify opportunities for improvement within our operations.
As we make progress toward our 2015 goal to improve energy efficiency in our manufacturing locations by 10 percent, it is important that we understand the causes of any changes in our year-over-year data. For example, our absolute usage of energy may increase simply due to our output of gallons of finished product increasing in line with the growth of our business. By focusing on continuous improvement in lighting, cooling, heating and production-line operations, we will strive to produce more with less on a per-gallon basis.
In 2011, we used approximately 270 million kWh of electricity in our manufacturing operations to produce approximately 1.6 billion gallons of product. This equates to usage of 0.17 kWh per gallon of finished product on a normalized basis.
Last year, we reported 276 million kWh used in 2010. While our total electrical consumption has dropped, we are not claiming this as year-over-year progress toward our goal due to changes in the way we measure gallons of finished product. Instead, we will use our 2011 numbers as the new baseline for our 2015 goal, reflecting the latest improvements in our data-collection processes. Our target for 2015 is 0.15 kWh per gallon of finished product.
Beyond our manufacturing locations, our commitment to energy efficiency and reducing CO2 emissions remains as strong as ever. All told, our operations, including corporate offices, distribution centers and other locations, used 315 million kWh of electricity in 2011.
Our ongoing RCI initiative has produced results that contribute to reduced energy use as well. In our warehouses, RCI activities continue to drive efficiencies in the storage and delivery of our products, frequently with an energy savings associated. Through a project focused on server consolidation, our IT department was able to decommission nearly 50 servers, freeing us from their costs and energy usage. With more than 150 RCI projects completed to date, we expect that these efforts, while focused on freeing up people, time and cash to grow the business, will continue to benefit our sustainability efforts in the future.
Our program to replace outdated vending machines and coolers continues to drive energy efficiency outside of our operations, lowering costs and improving service to our customers. In 2011, we replaced 13,000 older units with Energy Star-rated coolers and vending equipment, which combined with our 2010 efforts brings us more than halfway to our goal of replacing 60,000 units by 2015. Each unit represents an energy savings of up to 30 percent, yielding a total of 55 million pounds of CO2 removed from the atmosphere, as much as would be produced by 4,855 cars. In addition, the establishment of a new cold-drink equipment control process in our business will give us greater insight to where our equipment is being used and by whom, helping us to speed decision making on replacements in the future.