bakeshop energy audit

Managerial Design Review Friday, May 13, 2011

Customer: Wegmans Food Markets, Inc.Contact: Eric MacCormackGuide: John KaemmerlenP11713: Elizabeth Day, Chuck Nwapa, Carl Shatraw, Lucas Zamoyski

Project DescriptionMain Objective:

To determine an energy use benchmark by thinking about how to approach studying current state, identifying opportunities for improvement, and prioritizing them.

Challenge Collected available data

Many sources Over 20 documents collected

Integrate sources Break projects into categories

See Roadmap handout

Energy Types

Air Water Electric Gas

Improvements

Process Engineering

Energy Star Matrix ◦ Adapted for bakeshop◦ See handout for details

Energy Strategy for the Future

Shift demand to off-peak hours ◦ M-F 9pm to 9 a.m. & weekends◦ Production◦ Non-production (charging

equipment) Reduce utility delivery charges

◦ 42% lower rate for off-peak Base electric charge/supply can

possibly be renegotiated with ESCO

Usage profile available from RG&E

Billing Opportunities

Thermal leak checklist Oven startup time management

◦ Steady State Costs $8.14/hr @ 388o F $3.48/hr @ 212o F

◦ Transition costs are higher Undetermined at this point

Process Improvement

Heat recovery for ovens

Mixer motor replacement plan◦ See handout

Increase metering

Engineering Improvements

Energy Savings Savings Payback Period1 Shift $8,000 38 to 40 months2 Shifts $15,000 20 to 22 months3 Shifts $22,000 13 to 15 months

Performance vs. Specifications

Importance Description ProgressP9 Identify electric waste CompletedP9 Identify natural gas waste CompletedP9 Identify standard operating procedure(s) inefficiencies CompletedP9 Generate roadmap for future assessments CompletedP9 Identify solutions CompletedP9 Identify/execute "quick fixes" CompletedP3 Identify compressed air waste InconclusiveP3 Identify water waste CompletedP3 Identify unrecovered heat CompletedP3 Research billing structure CompletedS9 Refrigerant leak analysis InconclusiveS9 Calculate financial savings for system improvements CompletedS9 Prioritize energy methods CompletedS3 Improve lighting efficiency InconclusiveS1 Identify HVAC inefficiencies Out of scope

Future Work Light sensors in coolers Improve water management Improve conveyor management Standardize cleaning procedures New cooling equipment on cookie line Compressed air leak test Expand heat recovery opportunities

Thanks to all who contributed to this project!