Case History 4

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Food Processing

At the request of the supplying utility, an energy management survey was conducted for this 41,000 square foot meat processing plant located in the Midwest. The primary focus of the survey was to reduce electrical operating cost, with a secondary emphasis of upgrading the energy management skills of maintenance/operational personnel.

Areas of Investigation:

The systems and end use applications included in the survey were the plant electrical system (rate structure, power factor correction, controlling peak demand, etc.), AC electric motors, HVAC equipment, and interior/exterior lighting.

Survey Results/Savings Potential:

As a result of this survey, recommendations were provided to the customer that would reduce annual energy expenditures by $52,100, with a projected average simple payback of less than one year. This equated to a 10.5% reduction in annual electrical energy expenses.

Environmental Impact:

The recommended measures in this survey have the potential of reducing the amount of CO2 discharged into the atmosphere by 944,285 pounds annually. In addition, these measures can reduce the emission levels of SO2 by 7,480 lbs. and NOx by 2,915 lbs. each year.

A summary of the recommendations and their estimated annual savings is presented in the following table.

Table – Recommended Measures Case Study No. 4

RECOMMENDED MEASURES

ESTIMATED
COST($)

ESTIMATED ANNUAL SAVINGS ($)

SIMPLE PAYBACK
(YEARS)

Plant Electrical System

Install capacitors to correct power factor to at least 93%

$16,000

$33,600

0.5

AC Electric Motors

Utilize the MotorMaster+ software to select Premium Efficiency motors to replace existing units as they fail

$15,000

$7,100

2.1

Lighting Systems

Improve control of outdoor lighting

$200

$4,200

0.1

Utilize reduced wattage lamps and electronic ballasts in all production fluorescent fixtures

$4,000

$2,400

1,7

Keep HID fixtures in upper level room off until required

$ 0

$900

0.0

Replace incandescent fixtures in outdoor area with surplus mercury vapor fixtures

$300

$ 600

0.5

Add occupancy sensors to control the lower level change room fluorescent fixtures

$300

$400

0.8

Utilize reduced wattage Cool White fluorescent lamps in all office fixtures.

$ 0

$200

0.0

Compressed Air System

Repair all significant system leaks

$400

$1,400

0.3

Reduce the air compressor discharge pressure 8 psi

$ 0

$700

0.0

HVAC Systems

Utilize cogged V-belts on belt driven air handling equipment

$100

$600

0.2

TOTAL

$36,300

$52,100

0.7

For more information please e-mail to danccg@ipass.net

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