reducing kilowatts - · pdf filesysco case study 100+ food distribution centers (dcs) •...

Reducing Kilowatts

300,000 Foot View

© SmartWatt Energy 2012, All Rights Reserved

Establishing an Effective Distribution Center Energy

Management Strategy

Marcus Wilcox, President

Introduction to Cascade Energy, Inc. • Industrial energy efficiency consulting

– Experts in food processing, pulp & paper, petrochemical, manufacturing, etc. • Refrigeration, compressed air, pumping, fans, controls, process upgrades

– Worked on 700-800 ammonia refrigeration systems – Design and run utility efficiency programs serving >100 electric utilities

• Corporate energy management services for ~350 warehouses – Sysco (all DCs) – Ben E. Keith (all DCs) – SuperValu (all DCs) – Americold (all US & Canada PRWs) – Kroger Logistics, Others……

• We are like Consumer Reports – Don’t sell energy-using products – No brand or contractor preference

• Official EM Service Partner for International Association of Refrigerated Warehouses (IARW)

© Cascade Energy 2012, All Rights Reserved

Executive Quick Start – 10 Step Program 1. Discuss energy at

executive level 2. Assign an energy

champion or manager 3. Implement tracking

systems and establish KPIs 4. Set a savings goal 5. Set ROI hurdle for energy

projects

6. Leverage utility incentives & tax credits

7. Pursue low and no-cost opportunities

8. Identify, assess and implement capital upgrades

9. Benchmark against other facilities

10. Report progress across organization


Paths to Reduce Energy Cost 1. Implement Corporate Energy Management Executive

Support, Programs & Systems* 2. Pursue Low-Cost O&M Opportunities*

–Fixing Things –Tuning Things –Changing Your Ways –Commonly called “tune-up”, “commissioning” or “kaizen blitz”

3. Participate in Demand Response* 4. Implement Efficiency into New Construction* 5. Implement Retrofit Capital Projects* 6. Understand & Optimize Utility Rate Schedule *Often eligible for utility training or incentive programs


Sysco Case Study 100+ food distribution centers (DCs) • Freezers, coolers, dock, and

dry warehouse space

Rolled out program in March, 2006 • Announced by corporate

management • Managed by project

engineering group

Aggressive goals: • 10% after 1st year • 25% after 3rd year • Another 5% by 6th year

Four-Prong approach 1. Corporate goal and

commitment 2. Energy Information Systems 3. Tune-ups at every DC in 18

months 4. Retrofits and high-efficiency

new construction © Cascade Energy 2012, All Rights Reserved

Established Benchmarking System Cubic feet weighted by freezer, cooler/dock, and dry as well as average wet bulb for a normalized “Efficiency Factor” Near real-time monitoring of all major electric meters Entire company can be benchmarked • Rank within company • Rank within benchmark group • Rank within region This report is seen across company Requires monthly collection of 500+ utility bills


Sample Site Improvement Over Time


Baseline Companywide Performance Energy Use vs Facility Size - June Utility Bills

- 2,000 4,000 6,000 8,000 10,000 12,000

Weighted Cubic Feet

kWh/

day

2005


Performance After Tune-Ups Energy Use vs Facility Size - June Utility Bills

- 2,000 4,000 6,000 8,000 10,000 12,000

Weighted Cubic Feet

kWh/

day

2005

2007


Most Recent Performance


Energy Use vs Facility Size - June Utility Bills

- 2,000 4,000 6,000 8,000 10,000 12,000

Weighted Cubic Feet

kWh/

day

2005

2007

2010

Year to Year Performance kW

h/da

y/10

00 ft

3

Total Broadline Energy Intensity

2004

2005

2006

2007

2008

2009

2010

2011


Sysco Results

•Program started in 2006 •Total DC energy intensity (kWh/ft3) reduced by 1/3 •Savings to date = Over 1½ years of free energy!


Summary • Energy is one of your largest controllable DC expenses

– Refrigeration is the primary driver • Energy efficiency has excellent ROI • Results can be measured and documented

– “You can’t improve what you don’t measure” • Your strategy must be comprehensive to have deep and

lasting impact – Measurement, benchmarking, O&M, retrofit, new constr.

• Energy efficiency is a critical part of any meaningful sustainability or “green” initiatives


30,000 Foot View


Chris Covell, President

Who What Where Why

© Sm

artWatt Energy 2012, All Rights Reserved

Introduction to

Who: Turnkey Energy Efficiency Services Firm •Americold •US Cold •Price Chopper •Wegman’s

What : Energy Savings for Large Commercial & Industrial Facilities; Administer Utility-Based Energy Efficiency Programs Where: Headquartered in Albany, NY; 8 offices nationwide Why: Help businesses save energy and money; sustainability

© Sm


Eye Level View

Lighting


SmartThe right light, at the right place, at the right time.TM


The Right Light

Fluorescent

LED HID

© Sm


The Right Light

Randy Fletcher VP Logistics & Supply Chain Management

Fluorescent

LED


The Right Light Energy Savings?

Lumen Output?

Instant On/Off?

Optical Control?

Long Life?

Low Maintenance?

Large Utility Incentives?

Yes

Yes

Yes

Yes

Yes

Yes Yes © SmartWatt Energy 2012, All Rights Reserved

Fixture Location: spacing & height

Desired Light Levels

The Right Place


The Right Place


Albeo

Lusio Lithonia

The Right Place


Lights on when you need them, off when you don’t.

The Right Time save energy

reduce cooling load longer fixture life

EPAct tax savings

© Sm


The Right Time


The Right Time


Occupancy Sensors & Timers in

Offices


Beneath the Surface

Mechanical


VFDss

VFD Energy Savings

Avg. % Speed Reduction

Potential Energy Savings

10% 22%

50% 83%


ECMs

Savings 40-60%


Logic Based Control Systems

Savings 30%


Logic Based Control Systems

Gforce NH3 Control System



Other Mechanical Upgrades


Door Upgrades

Ammonia Refrigeration Upgrades

Boiler Upgrades

Units to Burn Waste

Oil for Heating


Beneath the Surface

Renewables

Wind


Solar


Cogeneration


Chris Covell [email protected]

Bryan Genevick

[email protected]

Marcus Wilcox [email protected]


http://www.cascadeenergy.com/default.asp�

reducing kilowatts - · pdf filesysco case study 100+ food distribution centers (dcs) •...

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