cynergy meat processing sector v2.pptx

COLD INTELLIGENCE

Meat Processing Sector Meat Processing Sector

INDUSTRIAL REFRIGERATION FACTS

Accounts for 30 – 70 % of Electricity Spend

Upto 50% More Than Is Required

The GOOD NEWS ?

Refrigeration Plants Can Be Optimised For Significant Savings With Little CAPEX

Meat Processing Sector Refrigeration Facts


• Plants are typically set up for ambient conditions which occur for less than 2 weeks of the year

• Maintenance contractors are incentivised to get plants up and running quickly, minimise call out frequency and duration – at the expense of energy efficiency

• Site facilities staff are typically not refrigeration experts

• Maintenance contractors rarely take ‘whole system’ view and their energy impact is rarely monitored

• There is typically minimal plant monitoring in place so the effects of sub par maintenance or process changes go unnoticed

• Process loads and conditions typically change over time and the plant is never recommissioned to optimally handle new loads and profiles

Why So Inefficient ?


Typical Meat Plant Refrigeration Requirements

• Carcass Chill – Chill carcass from 38 deg C to 7 deg C in 24hrs or less– Temp range -10 deg c to + 2 Deg C typically

• Maturing Chills – For maturing carcasses in – tenderise the meat

• Boning Hall– Legal requirement to keep at 7 deg C

• Blast Freezer – Cool product to -18 deg C in 24hrs

• Cold stores – Hold product at -22 deg C until transported off site


Meat Chilling Operational Factors

• Operate chillers to meet many mutually exclusive requirements,

namely:

– Minimise energy consumption

– Microbiological control

– Optimum surface fat condition and thus downstream productivity

– Cold shortening and appearance

– Weight loss

– Productivity

– Humidity Control

• Normally this is carried out with limited information and control


Common Issues in Meat Chilling

• Sub-Optimum Loading– Part loaded– Least efficient chiller first

• Peak load occuring @ peak electrical cost

• Doors open longer than required

• Wash down just before / during loading

• Poor defrost management

• Poor fan control

• Condensation


Efficient Refrigeration Control Best Practices

• Dynamically control and vary suction and discharge setpoints based on ambient and process conditions versus fixed setpoints

• Ensure compressors are controlled for optimal loading:– Screw Compressors are loaded in excess of 70% on average – Reciprocating Compressors acting as Trim compressors

• Intelligent dynamic control of distribution infrastructure– Pump VSDs (if secondary refrigerant used)

– Evaporator Fan VSDs – Electronic Expansion Valve control

• To Minimise Drip/Weight Loss– Minimise Temperature Differential (TD) between refrigerant and air– Minimise room air velocity


CONTROL is Key

Cynergy Dynamically Optimises The ‘Whole’ Industrial Refrigeration System

Production Needs

Ambient Conditions

Compressors

Condensers

Evaporators

EEVs & Pumps

Introducing ..


Introducing ..

Cynergy Pre- & Post-Implementation


Next-Generation Industrial Refrigeration Control Solution

Real-Time Adjustment & Balancing of Refrigeration Plant

Production Needs OPTIMALLY MET – ALWAYS

Removes 20 – 50% Energy Costs

No Cost To Client – Fully Paid Via Guaranteed Savings

Immediate Positive Cashflow & Control To You at No Risk

WIDESPREAD REFRIGERATION PERFOMANCE & EFFICIENCY ISSUES ACROSS SECTOR

90%

70%

60%

% of Our Client Base Had …

Energy Savings Delivered

15 – 40%

15 – 30%

10 – 30%

Inefficient Distribution System

Inefficient Compressor Start / Sequencing / Type

Additional Typical Inefficiencies Incorrect Condenser Piping – No Liquid Traps

No Utilisation of Free HeatDecentralisation of Plant / Inefficient PACKs

Manual Energy Consumption MonitoringRefrigerant Choice / Secondary Refrigerant Concentration

Inefficient or No Real-Time Control vs Production Needs & Ambient Conditions

INEFFICIENCY DRIVEN BY LACK OF CONTROL & NO PRODUCTION CONTEXT

Impact

• Fixed / Semi-Fixed Discharge & Suction Pressures

• No Ambient Condition Linkage• No Process Load Prediction Control • No VSDs on Condenser & Evaporators• No EEVs• No Defrost Optimisation

Inefficient Distribution System

Inefficient Compressor Start / Sequencing / Type

Inefficient or No Real-Time Control vs Production Needs & Ambient Conditions

Root Cause

• No Flow vs Process Load Control• No VSDs on Pumps

• Inefficient Load Sharing • No Part Load Optimisation• No VSDs• No Smart Starting and Trimming• No Compressor vs Secondary Pump Control


SECURE CLOUD-BASED REAL-TIME OPTIMISATION ENGINE & REPORTING PLATFORM

PRODUCTION FACILITY CLOUD / INTERNET

• CUSTOM DASHBOARD• ‘SPARK’ ALERTS• SAVINGS PERFORMANCE

MASTER


EFFICIENCY + PERFORMANCE = WINNNG STRATEGY

SECURE CLOUD-BASED REAL-TIME OPTIMISATION ENGINE & REPORTING PLATFORM

Inspired By Real-Time Formula 1

Data-Driven Decision Making Technology

~300 Sensor Inputs

Car Sensor Data (Telemetry) Sent

For Remote Analysis & Processing

Energy Conservation & Performance Optimisation Instructions

Returned to Car


CLOUD-BASED Cynergy FAR EXCEEDS TRADITIONAL LOCAL PLC FUNCTIONALITY ..

Plant Data Collected:

Ambient Conditions, Production Needs & Refrigeration Plant

Status

Telemetry Sent For Remote Processing

by Cloud-based Cynergy Logic

Engine200 Control Rules

C.O.P.

£££

C.O.S.P.

Optimised Refrigeration

System Setpoints Sent Back to Plant,

Monitored & Monetised

..i.e PREDICTIVE PRODUCTION REFRIGERATION OPTIMISATION, TARIFF REDUCTION


DIGITISE INSTALL M/C INTERFACES,VSDs, EEVs, AMBIENT CONDITION MONITOR etc BASED ON

COST BENEFIT ANALYSIS

OPTIMISE

MONETISE

CUSTOMISE LOGIC ENGINE TOWARDS PLANT OPTIMISATION

ESTABLISH SAVINGS BASELINE MODEL

CUSTOMISE DASHBOARD & REPORTING

3 MONTH ROLL-OUT JOURNEY(TYPICAL OVERALL IMPLEMENTATION TIMESCALE WITH LIMITED ONSITE WORK)

£££

£££s FLOW


DRAMATIC & IMMEDIATE CONTROL & EFFICIENCY IMPACT

£££

Major Project Undertaken


CUSTOMISED CONSUMPTION vs PRODUCTION DASHBOARDS

£££


TRACK ENERGY CONSUMPTION vs Kg PRODUCT RATIO

£££

21


TRACK REAL-TIME SAVINGS

£££


HOW ARE SAVINGS CALCULATED ?

£££ We have extensive experience optimising refrigeration systems in Meat Processing Plants

We have developed sophisticated models which predict energy consumption using up to 3 influencing factors

We then check the predictive model against historical usage data to establish a correlation or confidence factor - must be > 80%

Tracking Three Influencing

Factors


ADDITIONAL SAVINGS - RED ZONE PEAK CHARGE AVOIDANCE

£££


CYCLE OFF COLD STORES – CYNERGY CONTROLLED• Typically Cold Stores are on all the time

– Doors open for much of the day

• We would propose trialing turning the fans and compressors off for period(s) of the day – Up to 6hrs/day eventually – Drop suction temp to -38 deg C in advance of turn off

• This would be undertaken via a trial with customer – Trial how long it takes for temp to drift up

• One possible way of achieving this is running the cold stores to -26 deg C prior to electricity red band period – Let temperature float back to set point over the 2 hr red band period

• Contingency function:– If cold store temp goes 1 deg above set point turn the plant back on


Existing Plant

Existing M/C

Control

Existing Plant

Existing M/C

Control

!

COMMS FAULT ? CONTROL AUTOMATICALLY UNCOUPLED & DEFAULT MAINTAINED

Cynergy ONLY ADVISES – DRIVER (Existing Plant Control) STILL IN COCKPIT !


OUR STRAIGHTFORWARD OFFERING

£

OLD ENERGY

COST NEW ENERGY

COST

SAVING

FEE

GUARANTEED SAVINGS

PLUS CONTROL INFRASTRUCTURE

PLUS REAL-TIME VISIBILITY

PLUS REAL-TIME ALERTS

NO COST TO CUSTOMER

MONTHLY FEE FROM SAVING

THIS IS NOT BUSINESS AS USUAL – WE ASSUME ALL RISK

IMMEDIATE POSITIVE CASHFLOW

£

-£

Vendor Profits

TRADITIONAL PURCHASE MODEL

£

-£

You Get Immediate Cash Savings

We Assume All Risk

tAt Your Expense

t

TYPICAL FEE : £2,000/mthBASED ON £250K ANNUAL REFRIGERATION SPEND

20% REDUCTION IN ENERGY = £4,167/mth

TRUSTED CLIENTS OF

Bernard Matthews

Cranswick Group

Linden Foods

Tennents Lager

Johnson & Johnson

GE Healthcare

Direct Table Foods

Aliaxis Group

Emrill

COLD INTELLIGENCE

NEXT STEPSIf you would like to

understand the savings potential of Cynergy applied to

your refrigeration plant, please contact Crowley Carbon

to book a free initial Opportunity Assessment

www.crowleycarbon.com

[email protected]

+353 1 274 8880

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cynergy meat processing sector v2.pptx

Engineering