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INDUSTRY CASE STUDY

WINERY ENERGY MANAGEMENT - INDUSTRY STANDARD GUIDELINES

ENERGY MANAGEMENT FOR WINERIES ______________________________________________________________________________________________________

_______________________________________________________________________________________________________________ © Wines of Western Australia pg.1

Acknowledgements The Grape Wine Research Development Corporation (GWRDC) provided the funding for this publication through the “GWRDC regional grassroots solutions” program. In Western Australia this program is managed by Wines of Western Australia.

Wines of Western Australia thank Scott Favacho as the author of this publication and Keith Pekin (Perth Region NRM/Wines of Western Australia) who managed the development of the winery energy management project through funding provided through the Federal Government’s ‘Caring for our Country’ program.

Disclaimer

While every effort has been taken to ensure the accuracy and completeness of this publication, Wines of Western Australia accept no liability by reason of negligence or otherwise arising from the use or release of this information or any part of it.

In relying on or using any advice or information that has been expressed or implied and contained within this document, you accept all risks and responsibility.



Contents

Acknowledgements .............................................................................. 1

Contents ............................................................................................... 2

1. Introduction ................................................................................ 3

2. Energy Management .................................................................... 4

2.2 Lighting .......................................................................................... 4

2.4 Cellar Door ..................................................................................... 7

2.5 Winery ............................................................................................ 8

3. Refrigeration .................................................................................... 9

3.1 Restaurant/Cafe ............................................................................. 9

3.1 Cellar Door ................................................................................... 10

3.2 Winery .......................................................................................... 11

4. Hot Water ....................................................................................... 12

4.1 Restaurant/Cafe ........................................................................... 13

4.2 Cellar Door ................................................................................... 14

4.3 Winery .......................................................................................... 14

5. Heating, Ventilation and Air Conditioning (HVAC).......................... 15

5.1 Restaurant/Cafe ........................................................................... 15

5.2 Cellar Door ................................................................................... 16

5.3 Winery .......................................................................................... 17

6. Equipment ...................................................................................... 17

6.1 Restaurant/Cafe ........................................................................... 18

6.2 Cellar Door/Retail ........................................................................ 19

6.3 Winery .......................................................................................... 19

7. Tariffs ............................................................................................. 20

8. Funding .......................................................................................... 21

9. Waste ............................................................................................. 21

10. Appendix 1 – Australian Standard ................................................ 24



Introduction

Managing the environmental interests accompanying daily winery operations can deliver significant financial benefits and help reduce your greenhouse footprint. The key challenge for business owners and managers is determining the difference between worthwhile information and ‘green wash’.

Energy Management for Wineries has been developed to advise business owners of the options available for improving energy and waste management, without making specific reference to any particular brand, product or supplier.

This publication provides information on options for improving energy management in the following areas:

Lighting, Refrigeration, Hot water, Heating, ventilation and air conditioning, Plant and equipment, Tariff management, Funding opportunities and; Waste Management.

Within each of the above sections, energy management strategies address the following areas:

Restaurant/Café, Cellar Door and; Winery.

Systems should be developed to monitor the use of energy in the business, ensure compliance with waste management obligations and to track waste management costs. The use of electrical sub-meters are effective in monitoring and managing high energy use areas such as refrigeration, compressed air and lighting systems.



1. Energy Management In the daily operations of a winery, energy is used to achieve a large number of outcomes.

Typically, stationery energy, in the form of electricity, is used for lighting, chilling, heating and to operate motors and equipment, while gas is predominantly used for heating water. Some wineries in remote locations may use generators, often diesel powered, to provide extra electricity during peak usage periods.

It is important to examine where high levels of energy are used in operations and then target areas where efficiency is poor, improvements can be made for low or no cost, or areas where the most efficiency gains can be achieved.

The simplest actions can involve staff participation, such as turning lights and equipment off and ensuring that doors to air conditioned and chilled areas of the business are kept closed whenever possible. Other actions may require technological improvements, for example, installing variable speed controllers.

2.2 Lighting In contrast to systems used 10 years ago (which are now largely considered obsolete), in the last few years, energy efficient lighting technology has improved significantly. Due to the pace at which lighting and lighting control systems have improved, product suppliers often fail to keep abreast of new technology and may recommend inefficient products. It is therefore important to be aware of the latest technologies available before upgrading any systems. The ballasts and lamps employed in aged lighting systems pose an obstacle when replacing lighting systems, as old fixtures usually need to be removed before modern systems can be installed. It is worth establishing a return on investment timeline when looking at replacing lighting and prioritising the replacement schedule according to the level of efficiency of existing lamps and their workload or total energy usage. When selecting a lighting system, it is important to consider a number of factors: Adequacy for the job: Can the light provide sufficient lighting for

tasks to be performed safely? Can lighting level be increased or dimmed if necessary? Is light output the necessary colour (wavelength)? How often will the light be used and is it suitable for use with controls such as light (photo) or movement sensors?

Efficiency: How efficient is the system i.e. how well does the system convert energy (electricity) into useable light and not into heat?

Lifespan: How long do the lamp and system parts last? (This includes ballasts, starters and other components of the system)

When evaluating lighting costs and replacement options it is important to factor in all costs associated with normal use lighting, in a given area, over a minimum of a 10 year replacement cycle

Image 1: De-lamped fluorescent tube fixture



How much does the useable lighting level depreciate over the lifespan of the lamp? This is pertinent for lights located in high or inaccessible areas. Refer to Table 1.

Before examining ways to meet artificial lighting requirements, steps must be taken to assess and then utilise available natural light. It is recommended to make use of natural lighting by installing separate switching that can be turned off during the day in naturally well-lit areas.

Separate lighting switches allow lights in unoccupied areas to be turned off when not in use and should be installed in areas infrequently occupied.

Consideration should also be given to the length of time lights are left on. The simplest way to reduce the energy used is by communicating with staff that all lights must be turned off at the earliest convenience. When staff arrive at work, they should be encouraged to only turn on lights in areas they are occupying and to turn them off when they leave the work space.

Security and general lighting on timers should be readjusted according to the seasons or have photo sensors fitted to detect natural lighting levels and switch on/ off automatically. Motion sensor lighting should also be considered for exterior illumination. As well as reducing energy use, this could benefit the business in other ways such as deterring insects and vermin that may be attracted to light.

Lighting level requirements in work areas are specified in Australian Standard 1680 and an excerpt from this standard is reproduced in Appendix 1.

A lighting consultant is equipped to calculate lighting levels and ensure standards are met. Allowances should be made for depreciation when less light will be emitted from the lamp. Lighting level reductions of up to 30% on the initial lumen output are generally considered acceptable, but lamps should be replaced if depreciation continues.

For existing buildings, an inexpensive Lux meter can be used to determine lighting levels in various areas of the premises. Readings

Table 1: Lifespan for various types of lamps. L70 refers to the number of hours a lamp takes to depreciate to 70% of its initial lumen output able 1: Lifespan for various types of lamps. L70 refers to the number of hours a lamp takes to depreciate to 70% of its initial lumen output.



should be conducted at various times of the day to allow for fluctuating levels of natural light.

Storage and passageways are often the area’s most over lit and are therefore suitable for de-lamping. De-lamping is the process of removing the occasional lamp from fixtures and can be done at no cost. For the most savings, ballasts in de-lamped fluorescent fixtures should be removed by an electrician as these will still use up to nine watts of energy, even with the lamp removed.

2.3 Restaurant/Cafe Light Emitting Diode, or LED, and the latest in efficient fluorescent lighting are ideal for kitchen or food preparation areas. The use of incandescent lamps and halogen down lights should be avoided as these lamps convert the majority of their energy into heat rather than light, this also in turn increases the load on the air conditioning systems.

2.3.1 Light Emitting Diodes (LED) LED lighting is increasingly employed in everyday items, such as traffic lights, vehicle brake lights and car park floodlighting. Older LED technology struggled with high cost, low lighting output, and overheating, however, these issues have been addressed. LED technology is continuing to improve and as a result, they are generally considered the most efficient on the market. Although still relatively expensive to install, LED lamps last a lot

longer than most other lamps (>50,000 hours) and are durable and less likely to be affected by movement or accidental knocks,

Advances in technology have seen expansion into LED lighting in a range of colour spectrums. Practical applications include: use of a bluish/white lamp in food preparation areas and a yellowish/orange lamp in dining or cellar door areas to enhance ambience,

LED lamps work well with motion sensors as the frequent switching does not reduce lamp life as significantly as other lighting systems and there is instant re-start feature of the lamp,

Modern LED lighting systems do not convert as much energy into heat providing more useable light,

LED lamps are available in fluorescent style tubes as well as recessed general lighting and as a down lighting option and;

Ballasts are not compatible with fluorescent or halogen lighting systems so whole fixtures often need to be replaced which is an extra cost. For LED tube lighting, the existing reflector and housing can be used but the ballast must be disconnected / bypassed which, in Western Australia, requires the employment of an electrician.



2.3.2 Fluorescent Lamps The newer style of electronically ballasted, T5 fluorescent lamp is also a good option for meeting restaurant and café lighting requirements. This type of fluorescent fixture uses an electronic ballast, which is more efficient than older magnetic ballasts and offers longer lamp life, rapid re-start and improved lamp operation (lamps do not flicker start, electrical interference is reduced and fixtures do not hum). In some new fluorescent systems, lights can be dimmed but this is not typical. The T5 fluorescent tube (5/8 inch) is smaller than the traditional T8 fluorescent tube and uses around 30% less energy while delivering a similar result. Unlike LED systems, adaptor fittings are available allowing lamps to be installed directly into existing T8 fluorescent housings without using an electrician to disconnect and remove old ballasts. Compact fluorescent lamps (CFL) have better efficiency and lamp life than incandescent lamps and are a viable alternative to halogen down lights. Halogen down lights should be avoided as lamps are inefficient, have a poor lifespan (1,000 hours) and produce a lot of heat. LED and CFL replacement require switching of existing housings and ballast. A simple way to reduce energy used by these lights is to use a lower wattage lamp. A halogen down light has a typical wattage of 50W while a good quality 35W down light, with an infra-red coated dichroic reflector, can emit the same amount of light while using one third less energy.

2.4 Cellar Door The same principles apply for lighting in retail areas of the premises. Retail outlets have historically employed very high levels of lighting in an attempt to best promote their products. The use of inefficient halogen lighting is common for spot lighting or effect lighting in the retail sector. Traditional fluorescent systems, while efficient, tended to have limited colour spectrum options this issue has been addressed with the availability of recessed systems and more attractive reflectors. Inefficient lights convert more energy into heat than necessary and, as retail and cellar door areas are often air conditioned, their use should be avoided. General lighting should be provided by T5 fluorescent or LED lighting systems while spot lighting requirements can be met by the use of LED or CFL. An LED down light uses between three and 10 Watts of energy compared to a halogen down light which typically uses about 55 Watts of energy (including ballast).

Image 2: T5 adaptor kit



Typical lamp life spans for halogen lamps are 1,000 hours while CFL last for 10,000 hours and LED up to 50,000 hours (5.7 years continual operation). Counter and cabinet lighting needs can be met using LED lighting systems.

2.5 Winery Lights used in wine making areas often operate for long periods of time and are commonly positioned in high ceilinged areas. As a result, these lights tend to contribute to the bulk of lighting costs. For high bay lighting applications, the use of high intensity discharge lights or ‘Arc lamps’ such as sodium vapour, mercury vapour or metal halide lighting systems have traditionally been used as these systems were able to put out high levels of light at >4 metres height. Lumen depreciation or a reduction in light output is common with these older styles of lamps which can also be the source of significant levels of heat in areas commonly chilled.

Access when replacing lamps and lighting systems typically requires the use of a scissor lift in high ceiling areas so preference should be given to units that have the longest lamp life, best efficiency and the least lumen depreciation. For these reasons, it is hard to look past LED and Magnetic Induction Fluorescent (MIF) lighting systems for these areas, if working in concert with correct switching provisions. Both LED and MIF systems emit similar levels of light: less than half the wattage of traditional lamps. LED and MIF lamps also last two to three times longer than older, high bay style lamps, reducing replacement costs. Lighting systems should be capable of independent operation to ensure that lighting is only being used in areas immediately accessed. Walkways and passageways need be provided with a minimal amount of lighting with supplementary lighting provided above areas where processes are conducted and thus higher lighting levels are essential.

Figure 1: Lumen depreciation over time.



Another way to reduce the amount of energy required for lighting is to reduce the height of lighting fixtures. Lights should be located as close to work stations as practical, rather than at ceiling height, as lighting lumen decrease with distance. Use the recommended lighting levels in Appendix 1 and a Lux meter to relocate lights above areas where higher lighting levels are required and remove excessive lamps from storage, thoroughfare or excessively lit areas of the business.

3. Refrigeration Refrigeration accounts for the majority of energy usage in a winery, so, engaging the services of a refrigeration engineer/mechanic with energy efficiency experience is the logical first step in energy management.

Ensuring that the system is designed to meet the current needs of the business, with scope for expansion if necessary, and that it is properly maintained is central to getting the most out of your refrigeration system.

Emissions, or leaks, of refrigerant gas can also form a significant component of a winery’s greenhouse gas emissions as these gasses have very high global warming characteristics. Small leaks are generally unavoidable, so refrigerant charge pressures should be tested as part of regular maintenance.

Fortunately, modern refrigeration systems now focus on energy efficiencies, so it is worth evaluating the return on investment timeframe for a new fridge.

The efficiency of a system is rated in terms of its Coefficient of Performance (COP) which is a rating of power, chilling and output over input power. Generally speaking, the higher the COP, the more efficient the system.

There are still ways to save energy with existing systems by ensuring that refrigeration systems are properly used and maintained. For existing systems, the actions outlined in the following section can reduce the energy used for refrigeration.

3.1 Restaurant / Cafe Refrigeration needs are often met by a combination of domestic and commercial refrigerators, depending on the size of the kitchen and restaurant. The use of efficient display fridge units should always be given priority when selecting equipment. When in consultation with suppliers it is recommended to seek information about annual operating costs and COP.

Consolidating the number of fridges is one way to reduce energy costs. A central, well insulated cool room can be more efficient than operating three or four individual fridge units, particularly if old fridges are being

Image 3: Damaged condenser coils creating refrigeration system cooling inefficiencies



used. Reconsider the need to have numerous small bar fridges and staff fridges throughout the premises. A cheap power monitor can be used to monitor the power usage of fridge units so that preference can be given to the use of the more efficient units.

Fridges should be kept well stocked so that it is products and not air that is cooled, as chilled air is easily lost from the fridge every time the door is opened. The loss of chilled air can be minimised by ensuring that staff do not leave doors open when loading, unloading or cleaning cool rooms and by selecting horizontal rather than vertical freezer units.

Commercial refrigerators can use significantly more energy than domestic, especially if these units are oversized, contain glass doors or are inappropriately located near heat sources, for example, cooking equipment.

Some units will also have automatic defrost cycles which often use the most energy as heaters are used for defrosting. Defrost cycles can often be adjusted and shortened for a significant saving in fridge operating costs.

Glass display drink units are often provided ‘free’ by commercial drink companies are, as a rule, highly inefficient. Often, these fridges have lamps installed that can be disconnected. Disconnecting or turning off two 36W fluorescent fridge display lamps would save 800kWh of energy every year in lighting alone without taking into consideration the additional heat load these lamps contribute to the refrigeration load.

There may be an opportunity to turn some fridges off when the restaurant is closed. Non-perishable drink fridges and chilled water units could be fitted with timers so that these are turned off after hours.

Fridge compressors normally cycle on and off and this is, in part, determined by the thermostat setting on the units. Units that continually operate may indicate a problem with the thermostat or an unreasonably low thermostat setting.

For food safety reasons, hot food must be chilled rapidly after cooking or maintained above 60 degrees Celsius before storage. Avoid putting excessively hot food directly into the fridge or freezer by allowing it to cool down to 80 degrees Celsius before chilling.

3.1 Cellar Door Refrigeration provisions in the retail area of the business may include display fridge units with large surface areas of glass. Look for the build up of condensation around doors as this may indicate a damaged seal.

The temperature at which refrigeration units are set will also greatly affect efficiency, with reductions of up to 10% achievable by increasing thermostat settings by 1 degree Celsius. Food safety requirements demand that perishable food be maintained at a refrigerated temperature of <5 degrees Celsius. This may not be applicable in the retail areas of the business and it may be possible to increase

It is essential to locate refrigerators away from heat sources, such as cooking equipment and sunlight. External fridges and cool rooms should be provided with covers and shading so that they are kept out of direct sunlight.

If space is an issue, consider using insulating materials between the heat source and refrigerators/freezers.

Image 4: Poorly located fridge next to cooking equipment

Image 5: Missing freezer door causes more frequent and longer cycling of compressor.



thermostat settings to 7 degrees Celsius for the storage of wines and non-perishable items.

3.2 Winery The energy demand of chilling requirements is often responsible for over half of a winery’s energy use. Improving winery refrigeration efficiency can deliver significant energy savings and for this reason, should be given priority.

Detailed information relating to Winery Refrigeration Efficiency can be found on the Australian Wine Research Institute and Grape and Wine Research and Development Corporation’s web sites awri.com.au or gwrdc.com.au. Document titled ‘Improving Winery Refrigeration Efficiency’.

Winery refrigeration energy use peaks during vintage periods (February to April) as it is necessary to control the fermentation and wine production process.

Refrigeration needs in Western Australian wineries are often met by using air or water cooled brine systems. In these systems, brine comprising of water and an anti-freezing agent such as ethanol or salt is pumped throughout the winery to provide cooling. Warm brine then passes through a refrigeration plant where it is cooled to temperatures as low as -10 degrees Celsius, before being returned to the chilled brine tank.

Refrigeration plants in smaller wineries typically utilise air cooled and heat exchanges, while larger wineries generally employ water cooled condensers or a combination of air and water cooled condensers. Another option for larger wineries is the use of an ammonia based refrigerant plant, a method that is more efficient, but expensive.

The location of the refrigeration plant can maximise energy efficiency if located properly, ideally on the southern or eastern wall of the winery, in well ventilated and shaded areas out of direct sunlight.

Maintenance costs can be significant for older systems reaching the end of their rated life. Ensuring that condenser heat exchange coils are cleaned and maintained can increase the efficiency of your system significantly.

Replacing refrigeration plants incurs significant expense and assistance from external sources may be available. This could include low interest loans from Low Carbon Australia or dollar for dollar grants from AusIndustry that are currently on offer for the food manufacturing sector.

Chilling is required for the following processes:

Fruit chilling, Pressed juice and settling chilling, Fermentation chilling, Post fermentation chilling and;

Condenser coils should be cleaned regularly, particularly in dusty or oily environments. Build-up of dirt and grime can greatly reduce efficiency. Ensure that the evaporator coils inside the fridge do not ice up as this will restrict air flow in your unit.

Regular maintenance will improve refrigeration efficiency. Door seals should be kept clean and replaced if damaged or worn, as should missing freezer doors on combined fridge/freezer unit

Image 6: Ice build-up on a stainless steel wine tank. As with uninsulated brine lines, a build up of ice increases the surface area exposed to the environment and results in a greater loss of cooling energy.



Cold stabilisation

The energy used for the initial chilling of fruit can be reduced by night harvesting or conducting crushing and pressing activities during the cooler periods of the day. Fruit being stored prior to crushing should be kept out of direct sunlight.

To minimise cooling loss as brine is pumped through the winery, ensure that adequate insulation is provided for all chilled brine delivery lines and that this is regularly inspected and maintained.

Insulation around fermentation tanks and brine jackets can further reduce cooling losses as can properly locating fermentation tanks and providing shading from direct sunlight.

Utilising two brine tanks instead of a combined brine tank is another way to introduce energy savings. Some wineries use one brine tank which receives warm returned brine from the winery as well as chilled brine from the refrigeration plant. Separate tanks should be used, one for warm brine which can be chilled more efficiently by the refrigeration plant and another for chilled brine returning from the refrigeration plant.

Another benefit of utilising a second brine tank is that it increases the capacity of the brine system. For wineries employing ‘time of use’ or ‘peak and off-peak’ power tariffs, this can deliver significant cost savings as brine chilling can be scheduled to occur during off peak periods. The increased capacity in the brine system combined with higher set points on the thermostat during the day can reduce refrigeration plant operation during peak tariff times.

Brine temperature should not be set too low and can generally be increased for most processes with the exception of cold stabilisation when the product needs chilling to temperatures below zero degrees Celsius. It may also be possible to turn off the refrigeration plant if there is enough brine volume to maintain a sufficiently low temperature overnight or when there are fewer chilling requirements.

The use of variable speed pumps for brine delivery systems can significantly reduce pumping costs often by up to 50% and also prolong the pump and pump motor’s life span. The use of flow restrictors and throttling devices to slow brine flow rate should be discouraged and replaced by the use of variable speed controllers which can installed to maintain a set pressure or flow rate. The amount of energy spent pumping brine around the winery using VSD controlled motors can be reduced by using larger diameter pipes and minimising the length and number of sharp turns in the brine delivery system.

4. Hot Water Hot water is used in the winery for cleaning and sanitising purposes and also as a heating system to control fermentation.

Images 7 & 8: Damaged or missing brine line insulation.



A variety of systems can be utilised, however, the best system will often be conditional on a winery’s hot water needs and site location.

The opportunity to use solar hot water heating systems to pre-heat water should be investigated, as this would significantly reduce hot water energy costs. Heat exchanges could also be considered for pre-warming the hot water supply, as heat could be recovered from the refrigeration plant.

Heat delivery lines should be insulated to reduce heat loss, especially immediately after the hot water system where heat loss potential is at its greatest.

4.1 Restaurant/Cafe Food Safety Standards require that food premises be provided with warm water for cleaning and hand washing. This water should be heated to between 20 and 40 degrees Celsius. The amount of hot water required is contingent on the size of the business and can be best measured at peak periods.

Hot water can also be used for sterilising and is commonly used in commercial dishwashers as an alternative to chemical sanitisers. This requires water to be at least 77 degrees Celsius. Many commercial dishwashers have inbuilt heating elements that heat water to this temperature rather than relying on the main hot water system.

The type of hot water system used will be conditional on how often the kitchen operates. Instantaneous gas, solar systems and heat pumps can all be used and have different advantages.

Instantaneous gas systems can be very efficient and cheap to operate, however, natural gas availability is often an issue and LPG, which is a little more expensive, is typically used for gas hot water heaters.

Businesses that use a lot of hot water may also need a larger capacity than can be supplied by an instantaneous system, so a gas storage system may be necessary.

Electric storage systems are expensive and inefficient to operate, although these are often still used. Instant electric hot water heating would be a better option than electric storage if gas is not readily available or if hot water demand is low.

Solar hot water systems can be used to meet warm water requirements, although this would generally be more suitable for restaurants and cafes that operate during the day, unless a large storage capacity is provided.

A booster system, typically instantaneous gas, is required for times of insufficient sunlight. Many modern solar hot water systems will still be able to meet the warm water requirements required by the Food Safety Standards although; again this is dependent on the location of the winery, as well as level of demand.

Image 10: Hot water storage tank without insulation on out feed line.

Image 9: Line valve used to adjust brine flow

rate. Requires a VSD to manage flow in line

with requirements

Image 11: Timer installed to hot water system



Where solar hot water systems are unsuitable, heat pumps can also be used for restaurants and cafes. These are the most efficient type of electric system and can turn waste heat from refrigeration motors and other heat sources into hot water. Heat pumps may not be suitable for very cold climates and as heat pumps maintain constant temperature in storage so they are also not be best options for restaurants only open for a few days of the week.

Such premises would be better served by an instant system with no standing losses during times when the kitchen is closed.

Regardless of the type of water heating system, reducing thermostat settings can usually save energy. Hot water set points can be reduced to 60 degrees Celsius, unless water is required for sterilisation. This is the minimum required temperature for hot water systems as Legionella bacteria thrive in systems with lower temperatures.

It is recommended that hot water delivery pipes be insulated to reduce heat loss, particularly in storage hot water systems.

In kitchens or food preparation areas it is recommended that hot water delivery fixtures be fitted with low flow devices. For cold water applications, use cold water pre-wash nozzles, which deliver high pressure, at low volume.

Commercial, hot water dish washers use a significant amount of energy and therefore, should only be used when necessary and to wash full loads. Applying these measures will in turn use less water and conserve more energy from heat.

Timers on hot water urns and boiling units are a cost effective way to limit wasteful operating and reduce hot water standing losses. The cost of the device is often recouped in between three and six months.

4.2 Cellar Door If hot water is required in your retail or cellar door areas or where small glass washers are used, it is best to consider the use of instant hot water systems.

4.3 Winery Gas boilers, diesel boilers and electric storage units are amongst the most commonly used methods for hot water generation. While solar systems are relatively expensive to install, they demonstrate impressive longevity, are relatively maintenance free and can reduce hot water costs by 80% over its lifetime.

Beyond the everyday use of hot water for sanitation of tanks and equipment, warmed water is usually used for juice warming and the warming the finished wine prior to bottling.

Pre-heating options employing solar or heat recovery systems are worth further investigation. An insulated storage tank is used to store water heated by the solar system and/or heat recovered from the refrigeration plant.

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It is not uncommon for kitchen areas to be serviced by an evaporative air conditioning unit for supply air as well as an exhaust canopy and motor for ventilation during cooking.

However, some commercial kitchens have experienced energy savings by installing variable speed controllers to their exhaust canopy motors, where sensors in the canopy detect the amount of heat, steam, smoke or carbon dioxide and vary fan speeds accordingly.

Exploiting natural air circulation or breezes, if necessary assisted by fans, is the most efficient way to cool dining areas. Evaporative air conditioning units are capable of efficiently cooling large areas, however, are not effective in humid conditions. Evaporative units draw air from the outside to the inside so sufficient ventilation must be provided for these to work.

It is essential to minimise air loss in refrigerated air conditioning systems. Open windows and doors compromise the cooling and heating capacity of the system and result in unnecessarily lengthy compressor operation times and greater energy use. Conscious effort must be made to ensure doors are kept shut and window gaps sealed.

Decorative window dressings, such as thick curtains and pelmets, can minimise energy loss due to draughts and through glass which is a poor insulator. Reducing the length of time compressor motors operate can also be achieved by setting reasonable thermostat settings on your unit. A thermostat setting of higher than 24 degrees Celsius should be used in summer and a lower setting of 19 degrees Celsius in winter. Using the ‘heat’ setting in winter and the ‘cool/cold’ setting in summer, rather than ‘automatic’ settings can also deliver measurable savings.

Air conditioning compressor controller units are a relatively new technology that increases the amount of time compressors lie idle while the refrigerant decompresses. These units can be fitted to existing or new air conditioners and in some instances, claim savings of up to 60% in operating costs. Other new technologies include hybrid solar HVAC systems which use solar heated hot water to expand and compress refrigerant gas minimising compressor operating times.

5.2 Cellar Door Cellars are typically kept cool to maintain the integrity of the wine and create a comfortable ambient temperature for customers.

Temperature management is contingent on the size of the cellar, as well as the thermal mass of the building material. Buildings with high thermal mass and insulation can be kept relatively cool with little energy expenditure, while cellars or retail areas with a lot of windows or heat producing lighting will require greater levels of cooling.

Similarly to restaurant areas of the business, minimising the compressor motor operating time by setting reasonable thermostat settings,

Before investing in new technologies, it is important to review scientific and non-biased testing results. It is also recommended to discuss guarantees on system performance from suppliers and manufacturers based on your restaurant’s requirements.

Systems that utilise external cooling, such as the use of cross air flow ventilators, can also reduce winery HVAC energy use.

Generally speaking, it is more efficient to remove warm air using exhaust fans or ventilators than it is to cool the same space using air conditioning.

Image 14: Hybrid solar HVAC system



minimising cold air losses and the use of compressor motor controllers should be a priority.

5.3 Winery Investing in insulation can significantly reduce the need for winery air conditioning, often provided by a combination of refrigerated air conditioning units, evaporative units, fan ventilation systems and systems that utilise the existing chilled brine.

Some wineries restrict the use of air conditioning during the day when open doors can lead to high levels of cooling loss, and instead schedule runtime for during the night. This can also deliver benefits in terms of cost savings on wineries that utilise a Time of Use or Peak and Off-Peak tariff.

Co-generation, combined heat and power, and tri generation systems are another new heat, energy and cooling technology gaining popularity. Despite the high financial outlay associated with these systems, they generate electricity and hot water from one central system, thus reducing inefficiencies that arise from having separately operated systems.

Co and tri generation systems burn fuel to provide electrical energy, while using the heat generated from this process to supply heating and hot water. When combined with an adsorption chiller, waste heat can also be used to generate cold water to be used for chilling in the winery.

Co-generation and tri generation systems are very efficient to operate when compared to compressor refrigerant systems. Water is used in place of refrigerant thus eliminating the leakage of refrigerant gas: a significant source of greenhouse gas emissions in a winery.

6. Equipment Motor driven equipment and other electronic devices use a significant amount of energy to operate, however, savings can be easily realised by simply ensuring equipment is turned off when not in use.

Inspiring behaviour change amongst staff is the cheapest and simplest way to reduce equipment operating costs.

As part of the energy management process, staff should be encouraged to:

Report faults, Ensure equipment is maintained, Purchase energy efficient equipment and; Regularly monitor and report equipment performance.

All staff including cleaners and security personnel should be aware of their obligations with regards to saving energy.

As with most equipment, reducing the running time of the compressor will result in energy savings.

A regular maintenance program will include regular checks for leaks in the system which can add significantly to compressor operating times. Staff should be encouraged to report and repair compressed air leaks as soon as possible.

Image 14: Air‐line coupling are a common place for

air leaks



6.1 Restaurant/Cafe Equipment provisions in kitchen and restaurant areas of the business include items used for cooking food, keeping food warm, food preparation and cleaning.

Cooking equipment such as ovens and broilers, which typically require three phase power, tend to use the largest amounts of energy. Avoid selecting oversized units as it may be more efficient to invest in two smaller pieces of equipment for peak periods, and ensure that operating costs are factored in before selecting a unit.

Other energy intensive cooking equipment includes fryers, grillers, griddles, bain-maries, bratt pans, pasta cookers and salamanders.

Unlike office equipment, cooking equipment is unlikely to carry the Energy Star label in Australia, therefore, selecting efficient units must be determined by referring to manufacture specifications. These are expressed as kWh in electric equipment and MJ/Hr in gas. An efficient appliance can use half the energy of its inefficient alternative, so it is essential to factor in ongoing operating costs.

Minimising idle time can deliver significant energy savings, for no cost. This is especially critical during start up and shut down when only the minimum amount of equipment should be left operating.

The following actions can save energy in the kitchen:

Turning cooking equipment off when not in use, particularly when multiple units are in use. Alternatively, equipment can be turned right down,

Minimise hot air loss by maintaining seals and gaskets in and minimising door opening during the cooking process,

Minimise pre-heating times to the shortest period possible, Defrost food in the refrigerator; this reduces cooking time as

well as compressor operating time for the fridge, Ensure equipment, such as ovens and dishwashers, are full to

capacity before operating, Install or repair automatic door closures on equipment, Minimise operating periods and use of bain-maries and

warmers and turn these off as soon as they are no longer in use,

Select well insulated equipment and avoid the use of display warmer units with glass surfaces,

Locate heating equipment away from chillers, Consider the use of induction cooking technology that is proven

to be highly efficient, with short warm up time and offers better temperature control than conventional cookers,

Cook with the lid on pots whenever possible and encourage staff to use minimum settings to maintain boils,

Turn off coffee machines and warmers when not in use.

When selecting steamers, select units with enclosed steaming chambers rather than older, open style steamers. These will also reduce your water use.

For smaller kitchens using domestic type gas ovens, energy rating labels on these provide an indication of efficiency in terms of star ratings.



6.2 Cellar Door/Retail Equipment provisions in the retail and cellar door areas of the business are generally minimal and are generally limited to point of sale machines and a television or electronic advertising display. Small LED televisions are generally the most efficient to operate and again, it is recommended that all equipment be turned off after use.

For office areas, ensure that all computer equipment, printers and photocopiers have ‘power save’ or ‘sleep’ modes enabled and programmed to initiate at the earliest convenience. Disable screen savers and use the sleep mode setting on your monitor instead. Your server monitor can often be switched off and only turned on manually when necessary.

When selecting computer equipment, give preference to lap tops rather than desktop units and when printing, inkjets generally use less energy than laser printers.

6.3 Winery The most energy demanding piece of equipment in a winery is often the air compressor. Motors used for product transfer are another significant user of energy in winery operations. The use of variable speed drives (VSD) can often be considered in both applications to deliver energy savings.

The demand for compressed air in wineries fluctuates. However, it is vital to note that a continuous demand for compressed air indicates a leak in the system. Air compressors must be adequately sized for their application. In a typical unit’s ten year operating life, over 70% of an air compressor’s cost will be from basic operations, so it is important to select one that is adequate for the compressed air demands of the winery.

Many businesses make the mistake of installing a compressor, larger than necessary in size, to allow for expansion in the future. The sensible alternative to this is to install a compressor that will operate closer to peak capacity and add a back-up unit for periods of high demand. The secondary or back up compressor can be fitted with a variable speed control which reduces the speed at which the motor operates during periods of low demand.

Not only can a VSD save energy, especially when used with rotary or screw compressors which are quite inefficient at low or partial load, but the compressor motor is also placed under less stress during start-ups and shut downs.

For smaller wineries that only use a single air compressor motor, the use of a VSD compressor can similarly reduce motor speed and deliver significant savings of between 15 and 40%.

To determine if your system is leaking, let the compressor build up pressure during a period of minimal use, for example, during lunch break. Ideally, the compressor motor should not turn on again and the

Typical high efficiency induction motors can be cheaper to operate than VSDs if they are adequately sized and operate at close to or full load.

If motors are oversized, flow needs to be slowed or increased at certain times, then the use of VSD motor control could be beneficial.



system will not register any drop in pressure. It can be virtually impossible to identify and then seal all leaks in your compressed air system, particularly if it is large or old. For this reason, compressors should be turned off when no longer in use. Other maintenance includes cleaning and replacing filters which can block delivery lines and cause pressure drops in the system.

Ensuring that staff are not using compressed air for activities such as cleaning, blowing, mixing or cooling and that the provision of shut off valves for equipment not being operated, can also significantly reduce air compressor operating times.

Like the refrigeration plant, the compressor plant and equipment should be located in well ventilated, shaded areas, out of direct sunlight. This includes the inlet for the compressed air system which should be located away from heat sources such as the compressed air outlet or refrigeration or air conditioning plant and equipment.

Ensuring that air receivers are adequately sized, delivery lines do not contain sharp turns or narrow pipes and that the lowest possible pressure settings are used will also assist with energy efficiency. Consider installing larger receivers to store the compressed air as this minimises the constant starting and stopping of the compressor. The use of secondary receivers can be considered and should be located near the piece of equipment that uses compressed air rapidly, for example, the wine press.

Your compressed air maintenance provider or engineer will often conduct an air audit for little to no cost and may also be able to quantify savings in compressed air by utilising different technologies such as VSD controls. This typically requires compressed air use to be monitored for a period of time.

The use of VSDs for motor control should also be given preference over the use of physical throttling devices to slow product transfer. This allows flow rates to be more precisely controlled and can reduce motor energy use by more than half.

VSD controls for induction motors should be considered if average loads are typically 90% or lower.

7. Tariffs Electricity supply in Western Australia is competitive for businesses that use more than 50MWh of electricity per annum. Most medium sized wineries exceed this quite easily.

For businesses connected to the South West Interconnected System (SWIS), the default electricity supplier is Synergy. For businesses located outside the SWIS, Horizon Power is default electricity supplier.

As a significant portion of electricity is used for refrigeration and chilling, both of which run at all times, there is often a good case for accessing a Time of Use tariff. Utilising higher set points for brine systems during the day and result in significant savings as plant and



equipment is programmed to cycle on at night time when energy costs are significantly lower.

While this doesn’t actually result in less energy use, it does decrease demand on the local electricity grid during peak periods, resulting in less transmission losses and a more even demand pattern for the electricity generator.

Wineries that operate under a Time of Use tariff should seek to shift as much energy intensive processes to off peak periods to take advantage of the reduced electricity tariff rate.

8. Funding Funding from the Commonwealth to help meet the cost of improving energy efficiency is available through the Clean Technology Food and Foundries Investment Program.

This is a $200 million competitive program that provides funding for:

Replacement or modification of existing manufacturing equipment,

Changes to energy sources, for example, solar, gas, biodiesel, and;

Changes to manufacturing processes resulting in a reduction of carbon emissions through energy efficiency projects.

For more information, visit ausindustry.gov.au.

9. Waste Emissions from waste generated by winery operations significantly contributes to a business’s greenhouse gas footprint.

An easy way to reduce this footprint is to minimise the amount of waste generated in the first instance by minimising and reusing packaging such as cardboard and pallets.

The GWRDC has published a lot of information on waste water management for wineries, all of which is available at gwrdc.com.au.

Identifying the type and volume of waste produced is the first step toward actively reducing or eliminating. Solid waste generation to landfill can be reduced by modifications to work, equipment or production processes, by recycling and reusing materials.

It may be possible to ask suppliers to reduce packaging or arrange for packaging material to be returned for reuse.

Organic waste has the capacity to emit the most greenhouse gasses, depending on the method used for disposal. Organic solid waste is generated through crushing and pressing which leaves skin, vine, seeds and pulp. ‘Lees’ or the sludge at the bottom of fermentation tanks and in wastewater streams also contains a high proportion of organic matter.

Composting organic waste from winery operations can turn a waste product into a soil conditioner. Establishing a composting system on site

Recycling services near regional centres will usually be available for glass, cardboard, paper, metals, plastic containers and clean plastic wrapping.

Waste that is not sent to landfill is not liable for the landfill levy so it is often cheaper to separate your waste and send it to a recycler than it is to send it to landfill.

Images 15 & 16: Separation of waste streams for

recycling



will take between 10 and 12 weeks, after which time most weeds and pathogens in the mix will be destroyed. For best results, regular aerating or turning of the rows should be conducted to prevent the production of methane and the associated odour.

The use of grape marc as a potential bio-fuel is also being investigated and trialled in Australia. While still in infancy, regionally located centres could accept grape marc, which has a high calorific value and a similar energy content to brown fuel, and turn this into a renewable energy returned to the grid.

The use of grape marc and vineyard waste may also have potential for use as ‘biochar’ which is produced by burning waste at high temperatures under low oxygen conditions. Compared to simply burning waste, turning it into biochar inspire improved soil conditions and water retention capabilities. Biochar also has the ability to store carbon in soil because the carbon content of biochar is significantly higher than the carbon content of grape marc. Rather than releasing this carbon into the environment by incineration or disposal to landfill, the carbon is stored in the soil and not easily released into the atmosphere.



10. Appendix 1 – Australian Standard 1680 Part 1 – 1990, and AS/NZ 1680.2.4 1997.

Table 1 – Recommended minimum light levels

Minimum Illuminance (lux)

Task difficulty and examples

40

Corridors, walkways

80

Change rooms, loading bays, bulky storage.

160 Simple tasks. Waiting rooms, rough bench work, general fabrication

240 Moderately easy tasks. Food preparation areas. Medium woodworking

320

Moderately difficult tasks. Routine office work

400

Moderately difficult tasks. Fine woodwork

600 Difficult tasks. Drawing boards, inspection tasks, fine machine work, fine painting, colour matching

800 Very difficult tasks. Fine inspection tasks, colour matching of dyes.

1200 Extremely difficult tasks. Graphic arts inspection, extra fine bench work

1600

Exceptionally difficult tasks. Jewellery, watch making

Extract from Table 3.1 AS 1680.1 – Recommended Maintenance Illuminances for Various Tasks, Activities or Interiors

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