Optimizing Resources For Improved Performance

CIPEC Energy Summit 2018

GAY LEA FOODS CO-OPERATIVE LTDMAY 30, 2018

ZBIGNIEW EWERTOWSKI, P.ENG.DIRECTOR, OPERATIONS TECHNOLOGY

GAY LEA FOODS CO-OPERATIVE LTD.5200 Orbitor Drive

Mississauga, Ontario

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GAY LEA FOODS briefly:

• 11 manufacturing facilities: 9 in Ontario, 1 in Manitoba, 1 in Alberta

• 662,000,000 litres of milk processed in F2017 (bovine and goat combined)

• Employees: 1,012• Sales in F2017: 788 M

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Gay Lea range of products:

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Fluid milk, Cream, Whipped Cream, Various Cheeses, Cottage Cheese, Sour Cream, Butter, Milk Powder, Yoghurt

SPECIFIC NATURE OF DAIRY INDUSTRY

1. Biologically active substrates – dynamic in nature2. Perishable foods3. Shear sensitive4. Heat treatment to destroy pathogenic microorganisms

and extend shelf life:- Pasteurization and sterilization- Refrigeration and freezing- Concentration and Drying

5. Sanitary aspects6. CFIA compliance

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SAVING ENERGY AND WATER

SAVING ENERGY AND WATER MAKES SENSE FROM ABUSINESS & ENVIRONMENTAL PERSPECTIVE

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ENVIRONMENT

Environmental issues specifically associated with dairyprocessing facilities include the following:• Wastewater• Solid waste• Emissions to air• Energy consumption

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BENCHMARKING PROCESS

• By benchmarking energy and water intensity against a known

reference dairy process we can evaluate the energy and water

efficiency of our processes

• The reference dairy process is based on existing and proven

practices and technologies identified from available sources.

• Benchmarking can be used as an energy management strategy

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BENCHMARKING cont’d

• The benchmark score values can be used to indicate relative performance of our dairy process compared to the most efficient process identified e.g. European BAT (Best Available Technology).

• The outcomes from comparisons may become a basis to evaluate potential for savings and to consider future improvements

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KPI

We develop KPIs for what we can control at the plant operations

level. Key metrics include reducing kWh of electricity, m³ of

natural gas and water, and kg of BOD concentrations

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EXAMPLES FROM THE BENCHMARKING PROCESS

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PLANT "A" Electricity Usage (2016)

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0.138 0.1370.150

0.136

0.161 0.1670.180

0.163 0.168 0.171

0.148

0.222

0.000

0.050

0.100

0.150

0.200

0.250

kWh

adj./

Litr

e M

ilk

Month

Electricity (kWh adj./L) Average

Plant "A" Natural Gas Usage (2016)

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0.022

0.0250.023

0.0210.021

0.018

0.0150.017

0.018

0.020 0.021

0.027

0.000

0.005

0.010

0.015

0.020

0.025

0.030

Cub

ic M

eter

/Litr

e M

ilk

Month

Gas (m3/L) Average

Plant "A" Water In Usage (2016)

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3.3883.696

4.026

3.502

3.9953.732 3.694

3.3103.650

3.899

3.422

5.187

0.000

1.000

2.000

3.000

4.000

5.000

6.000

Litr

e W

ater

/Litr

e M

ilk

Month

Water In (L/L) Average

Plant "A" Wastewater Generation (2016)

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3.0822.750 2.877

2.520

2.890 2.804 2.8232.555

2.785

3.1622.810

4.827

0.000

1.000

2.000

3.000

4.000

5.000

6.000

Litr

e W

ater

/Litr

e M

ilk

Month

Water Out (L/L) Average

GAY LEA FOODS’ RESOURCES SAVING INITIATIVES

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WATER

• Reduction of demand for water in processing

• Reduction of demand for water in cleaning

• Reduction of demand for water in utilities

• Water recycling and reuse

• Wastewater treatment processes

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ENERGY: ELECTRICITY AND HEAT

• Conducted Audits to identify opportunities • Implementation of the findings in the compressed air and

steam• Heat recovery

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YIELD OPTIMIZATION AND PRODUCT RECOVERY

• Sources of product loss

• The cost of product loss

• Efficient processing and process control

• Minimizing waste

• Maximizing product recovery

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GOAL

Reduce first, Recover-Reuse last

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Q&A

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