Compressed air retrofit reduced risk of product contamination at food plant
At a food processing plant we found that air compressor room was dirty and water was going on the floor all over it.
“That’s no problem. Product never enters this room. Compressed air does not come into contact with product, it’s used mainly to operate packaging line” – said maintenance manager. Audit brought to plant manager’s attention a simple observation that packaging machine exhausts compressed air in close proximity to unpacked product. A complex retrofit of compressor room was soon underway.
Optimization of refrigeration plant saved 34% of energy at food processor
Industrial refrigeration plant is an energy hungry complex set of machinery. It can reject the same amount of heat (‘produce the same amount of cold’) using different amounts of electricity depending on settings.
A typical refrigeration plant wastes 20-40% of energy.
Having efficient compressors does not guarantee efficient operation of the whole plant. The way fans, pumps and compressors are set to work together can make a 34% difference in energy consumption.
Energy audit can recommend energy efficient settings and operational procedures.
Lighting retrofit eliminated production bottleneck and saved CAPEX at industrial bakery
That was a curious case. Energy was not at top of plant manager’s mind: demand for their baked goods exceed their production capacity. Freezer was the bottleneck. Their product was shipped frozen and could not freeze as much as they could bake. Freezer was the bottleneck. Plant manager was working on CAPEX request to HQ for a bigger freezer. HQ was not supportive: rebuilding freezer would cause production interruption, while product was in demand. As a temporary measure plant sent a truckload of product to a 3rd party freezer for about $500 per truck, every day, every shift.
An express audit of the facility uncovered that their freezer had metal halide lighting. Effectively a 6kW heater within a freezer.
Long story short, an LED retrofit for this freezer eliminated the bottleneck and saved a truckload of cash: this project had a 3 day payback with no interruption for production.