capacity — such as conveyors belts in a packaging line — calculations are usually sufficient
to determine the system’s annual energy use.
Step 4: Obtain the electric, natural gas,
purchased chilled water and steam negotiated
utility rates for the project. Convert the annual
energy use to annual energy cost, and calculate
the energy cost per product using the information collected in Step 3. It might be helpful to
use a 20-year averaged energy cost that takes
into account energy cost escalation for each
utility type. When calculating the energy cost
per product make sure to use the anticipated
annual production capacity of the facility when
it is under full operation.
What is the best way to identify energy
reduction strategies that have the most
impact on the energy cost per product KPI?
Based on the energy use calculated for the
different uses in the plant in Step 3 above, identify energy reduction areas and corresponding
energy reduction strategies. It is important to
look at both energy use and energy cost impact
when identifying which energy reduction strategies to implement.
While natural gas used for process heating,
sterilization and emission control is the largest
energy use component in many food and bev-
erage manufacturing facilities, in many cases
installing energy reduction strategies for natural
gas use reduction may not translate into a 1:1
energy cost savings/product. This is because in
many cases, natural gas is typically four to five
times cheaper than electricity. Reducing natural
gas use may show substantial energy savings
but not a big energy cost savings.
Continuously update the annual energy use/
product and annual energy use cost/product
throughout the design process to track progress
and to ensure that the project stays on track.
What is the most effective way to set up
and continuously track all this information?
Given the time sensitivity and complexity of
the energy cost per product calculation, it is
best to have one entity in charge of managing
the overall plant energy performance tracking.
There are many designers involved in a food
and beverage plant design, and the variables
involved in the design evolve constantly. In
order to track and affect the overall energy per-
formance of the project effectively, there needs
to be a central person to facilitate the process,
with oversight to look at all energy-related
information and bring it together in cohesive
manner. This way, there will be a single respon-
sible party in charge of tracking the energy
performance goal, updating calculations as the
design changes and examining the impact on
energy performance KPI.
The above process has helped multiple food
manufacturing projects improve energy performance in the range of 10-30 percent compared
to industry standards and reduce annual energy
cost in the range of 8-25 percent. Given annual energy bills can be in the range of $12-15
million, overall savings may amount to $14-60
million over a fifteen-year operation period. This
number will be even higher if utility rate escalation is taken into account.
In addition to direct energy cost savings,
establishing the energy cost per product KPI
early in the design process and continuously tracking improvement during design and
construction provides a host of other benefits.
The project will be well positioned to achieve
USGBC’s LEED certification and it will have a
well-established energy performance target for
the operational phase. In addition, this information can be used to apply for utility incentives,
providing added cost savings to the owner. ◆
A better way to
wash and sanitize
scale parts is right
at your fingertips!
CALL 800-331-6870 for pricing, literature and specifications on a model suited to your needs.
2101 CALUMET ST. • CLEARWATER, FL 33765 • (727) 461-3477
(800) 331-6870 • FAX(727) 449-0029 • www.dougmac.com
Hang up your gloves.
Presenting the Douglas Model 1536-SPW.
Meet today’s high standard for cleanliness and sanitation
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with a ramp, this walk-in type batch washer cleans scale parts
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detachable items. This powerfully efficient machine also features
pre-programmed wash times and a digital display that monitors key
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wash/rinse cycle of just 5 minutes, clean-up is quick and economical!