Natural Resources Canada
Symbol of the Government of Canada

Office of Energy Efficiency Links

 

Business: Industrial

Features


CIPEC Heads Up

Industry calendar of events

Heads Up CIPEC

January 1, 2010 Vol. XIV, No. 1

This issue is devoted to highlights from Energy 2009 – Lean and Green, Canada's foremost industrial energy efficiency conference


Articles

Strong turnout for Energy 2009

On November 24 and 25, more than 400 participants attended Energy 2009. The conference was co-hosted by NRCan’s Canadian Industrial Program for Energy Conservation (CIPEC) and Canadian Manufacturers & Exporters (CME) – a member of CIPEC and a leader in promoting energy-saving practices to industry.

The biennial event was kicked off by master of ceremonies Susan Olynyk, Senior Specialist, Climate Change at ArcelorMittal Dofasco and Chair of the CIPEC Task Force Council. The two-day event featured more than 20 workshops and panel sessions presented by the country’s leading energy experts, industry leaders and energy efficiency suppliers.

As Jayson Myers, President and Chief Executive Officer of Canadian Manufacturers & Exporters mentioned during his opening remarks, “Energy efficiency will be the lynchpin for addressing climate change and delivering bottom-line benefits to manufacturers in the form of cost savings and productivity improvements that will make manufacturers more competitive – that’s the win-win for the economy and the environment.”

Back to top.

CIPEC Leadership award winners energize the bottom line with energy efficiency

Ten companies that are working at the forefront of an industrial energy efficiency revolution were honoured at the CIPEC Leadership Awards on November 24. This signature event of the Energy 2009 conference was attended by more than 400 industry leaders.

From more energy-efficient ways to manufacture potato chips, aluminum and beer, the awards covered a cross-section of Canadian industry. And while the winning projects were as diverse as the products they represent, all had one thing in common.

“The winners all showed an outstanding commitment to improving industrial energy efficiency. They are all the kind of lean and green organizations that are energizing their bottom line with energy efficiency,” said Glenn Mifflin, Vice-President and Chief Financial Officer of North Atlantic Refining and Chair of the CIPEC Executive Board. According to Mifflin, master of ceremonies for the awards dinner, “We have to spread the message that energy efficiency remains the most cost-effective way to avoid emissions. This is good news as we face a carbon-constrained future. It’s also good news in these tough economic times when every penny we spend must be justified.”

Photo 1

Glenn Mifflin, Vice-President and Chief Financial Officer of North Atlantic Refining and Chair of the CIPEC Executive Board presenting CIPEC’s 2009 Annual Report – Energizing the bottom line with energy efficiency

Mifflin was joined by Malcolm Brown, Associate Deputy Minister of Natural Resources Canada (NRCan), Carol Buckley, Director General of NRCan’s Office of Energy Efficiency, and Mike Burke, Director of NRCan’s Industrial Programs Division to present the awards.

Before the awards ceremony began, Brown brought greetings and congratulations from the Honourable Lisa Raitt, Minister of Natural Resources Canada. He also congratulated all CIPEC members for the fact that CIPEC was declared a 2009 Champion of Energy Efficiency by the American Council for an Energy-Efficient Economy. The Council is a leading centre of expertise on energy efficiency in the United States. Its technical work is relied on by policy-makers, business and industry decision-makers, consumers, and the media.

“This award belongs to everyone in the CIPEC family – in both industry and government. We won it because we are truly passionate about improving energy efficiency,” Brown said.

Award Winners

Plenty of that passion was on display as the CIPEC Leadership Awards ceremony unfolded. Nominations were submitted by CIPEC Leaders from across the country. Each nomination was evaluated against five criteria: impact on energy efficiency; innovation; potential for broader use; environmental impact; and cost-effectiveness. Two awards were presented in each of five categories:

Corporate stewardship winners: Frito Lay Canada (25 locations across Canada) and la fromagerie St-Guillaume (St-Guillaume, Quebec). For projects that promote energy efficiency at the corporate level – for example, by creating an energy management team or developing a corporate energy management plan.

Frito Lay Canada established employee-based Green Teams, led by a sustainability leader, in all of its facilities in 1993. Energy efficiency initiatives include the installation of heat recovery systems at all Frito Lay plants. The company also upgraded insulation, retrofitted lighting, conducted compressed air audits and improved metering of energy use at many of its plants. All told, Frito Lay is reducing water consumption by 34 percent, natural gas consumption by 25 percent and electricity consumption by 18 percent.

Photo 2

From left to right: Glenn Mifflin, Vice-President and Chief Financial Officer of North Atlantic Refining and Chair of the CIPEC Executive Board, Helmi Ansari, Sustainability Leader, Frito Lay Canada and Malcolm Brown, Associate Deputy Minister, Natural Resources Canada

At la fromagerie St-Guillaume, an energy champion mobilized staff and conducted an energy audit. The resulting planning and implementation of energy efficiency projects, such as upgrading the plant refrigeration systems and process drying equipment, reduced annual total plant energy consumption by 35 percent. These projects have also allowed the plant to cut 1733 tonnes of greenhouse gas emissions a year.

Photo 3

From left to right: Glenn Mifflin, Vice-President and Chief Financial Officer of North Atlantic Refining and Chair of the CIPEC Executive Board, Ghislain Gervais President and Pierre Tremblay, Plant Manager, la fromagerie St-Guillaume and Malcolm Brown, Associate Deputy Minister, Natural Resources Canada

Process and technology improvements winners: MIRALIS (Rimouski, Quebec) and McCain Foods (Canada) (Carberry, Manitoba). For projects involving changes to equipment and procedures that reduce the energy intensity of an industrial process.

MIRALIS, a kitchen-cabinet manufacturer installed an on-demand HVAC control to handle ventilation needs of 125 work stations. The upgrade reduced the dust collection system’s energy consumption by 50 percent. MIRALIS also upgraded its lighting system – cutting electricity consumption related to lighting by about 45 percent. These reductions in energy consumption represent annual savings of 2300 gigajoules (GJ), or around $50,000 in electricity costs.

Photo 4

From left to right: Glenn Mifflin, Vice-President and Chief Financial Officer of North Atlantic Refining and Chair of the CIPEC Executive Board, John Parrot, Representative, Ontario Region, MIRALIS inc. and Malcolm Brown, Associate Deputy Minister, Natural Resources Canada

McCain Foods’ potato processing plant is recovering heat from fryer vapour with a two-stage energy recovery system (ERS); the recovered heat is used to heat water in the pre-heating process, saving the plant an average of 125 GJ every day. The ERS control system has liquid and air flow meters and temperature sensors that help staff optimize the system’s performance and identify as many energy-recovery savings as possible. This approach is making the plant one of the lowest-cost facilities in the McCain Food family.

Photo 5

From left to right: Glenn Mifflin, Vice-President and Chief Financial Officer of North Atlantic Refining and Chair of the CIPEC Executive Board, Len Bull, Maintenance Supervisor – Utilities and Justin Walsh, Plant Manager, McCain Foods (Canada) and Malcolm Brown, Associate Deputy Minister, Natural Resources Canada

Monitoring and tracking winners: Redpath Sugar Ltd. (Toronto, Ontario) and Alcoa Canada Première fusion (four locations in Quebec). For projects that enhance a company’s ability to provide accurate reports on energy consumption for facilities or across entire companies.

Redpath Sugar implemented an energy-benchmarking system that uses regression models to identify and manage energy use. The company also employs a full-time Energy Manager who reports each month on daily energy consumption. Energy monitoring has led to energy-efficient projects that have reduced natural gas consumption by 67 000 GJ a year. Projects included installing a flash steam recovery system, process upgrades, boiler and tank insulation and the addition of a buffer tank to prevent sewering condensate from the hot water tank.

Photo 6

From left to right: Glenn Mifflin, Vice-President and Chief Financial Officer of North Atlantic Refining and Chair of the CIPEC Executive Board, George Carter, Process Manager and Narayanan Seshadri, Energy Manager, Redpath Sugar Ltd. and Malcolm Brown, Associate Deputy Minister, Natural Resources Canada

Aluminum producer Alcoa Canada Première fusion tracks and monitors the energy consumption of its 34 industrial furnaces at its four facilities and reports monthly to regional management and the regional energy committee. High or unusual patterns of energy use are investigated, and corrective action is taken. The resulting annual energy savings are around 27 percent, with a reduction of around 15 000 tonnes of greenhouse gas emissions annually.

Photo 7

From left to right: Glenn Mifflin, Vice-President and Chief Financial Officer of North Atlantic Refining and Chair of the CIPEC Executive Board, Francis Caron, Director Research and Development and André Beaulieu, Energy Leader, Alcoa Première fusion and Malcolm Brown, Associate Deputy Minister, Natural Resources Canada

Employee awareness and training winners: Husky Injection Molding Systems (Bolton, Ontario) and Molson Coors Canada (Vancouver, British Columbia). For developing a broader awareness and understanding of energy efficiency opportunities among employees, adopting best practices and demonstrating the environmental and economic advantages of energy management.

Husky Injection Molding Systems’ employee awareness and training has three elements: an energy-awareness education program, an energy challenge and an engineering engagement program. New Husky employees receive sustainability training as part of their orientation. In addition, the engineering engagement program helps Husky drive energy efficiency throughout its manufacturing process. Creating an energy efficiency awareness culture helped Husky reduce its energy use by around 17 percent between June 2007 and August 2009. Installing sub-metering has helped realize annual energy savings in electricity consumption of 19 000 GJ.

Photo 8

From left to right: Glenn Mifflin, Vice-President and Chief Financial Officer of North Atlantic Refining and Chair of the CIPEC Executive Board, Al Fiacco, Facilities Manager and Ryan Fabi, Director, Environment, Health and Safety, Husky Injection Molding Systems and Malcolm Brown, Associate Deputy Minister, Natural Resources Canada

The Molson Coors’ Vancouver brewery energy-conservation program increases awareness among employees about the importance of energy efficiency in day-to-day operations. Energy targets and results are reported monthly. The awareness program has led to projects like the redesign of the brewing kettle steam systems, which is reducing energy use by 5800 GJ and avoiding 288 tonnes of carbon dioxide annually. A refrigeration study resulted in electrical savings of 6000 GJ per year. Replacing the incandescent light bulbs in the Molson signage with LED bulbs is saving 700 GJ per year.

Photo 9

From left to right: Glenn Mifflin, Vice-President and Chief Financial Officer of North Atlantic Refining and Chair of the CIPEC Executive Board, Scott Gordon, Chief Engineer, Molson Coors Canada – Vancouver Brewery and Malcolm Brown, Associate Deputy Minister, Natural Resources Canada

Integrated energy efficiency strategy winners: Alberta Newsprint Company (Whitecourt, Alberta) and Broan-NuTone Canada (Mississauga, Ontario). For projects that use a combination of initiatives to reduce the overall energy consumed at a facility or by a company.

Alberta Newsprint established an energy conservation team to lead an integrated energy efficiency strategy focusing on reducing electricity consumption. Since 2008, 35 projects have been implemented, covering everything from regular cleaning and maintenance to the adoption of innovative technologies. These projects include removing energy-intensive pulp cleaners, secondary pulp screens and major tanks and accessories and optimizing pulp mixing and agitation equipment. The company has removed about 5300 horsepower from plant processes and is delivering energy savings of 100 000 GJ annually.

Photo 10

From left to right: Glenn Mifflin, Vice-President and Chief Financial Officer of North Atlantic Refining and Chair of the CIPEC Executive Board, Léo Dubé, Shift Coordinator, Alberta Newsprint Company and Malcolm Brown, Associate Deputy Minister, Natural Resources Canada

Broan-NuTone, a producer of residential ventilation products, is home to a cross-functional energy team, with members drawn from key departments, mandated to reduce process energy consumption. Projects include using new chemicals that clean at lower temperatures and recycling process water – reducing water consumption by around 80 percent and cutting water-heating costs. Other projects involve recirculating compressed air and reducing dry-off oven temperatures, which cut natural gas and electricity consumption by 4500 GJ per year.

Photo 11

From left to right: Glenn Mifflin, Vice-President and Chief Financial Officer of North Atlantic Refining and Chair of the CIPEC Executive Board, Rodier Grondin, Vice-President of Operations, Broan-NuTone Canada inc. and Malcolm Brown, Associate Deputy Minister, Natural Resources Canada

Back to top.

Lean, green and profitable – focus of workshop

Participants at the workshop “Energy Efficiency as a Co-benefit of Lean Manufacturing“, presented on November 24 at Energy 2009, learned that if it’s good for the environment, it’s probably good for business.

“Going green isn’t about doing the right thing and being warm and fuzzy. Going green is about competing in the global marketplace,” said presenter Brett Wills. He is Global Director of the Green Enterprise Movement and a senior consultant with High Performance Solutions Inc.

Wills is concerned with waste in all its forms. He challenged the audience to explain why it’s still acceptable business practice to pay to create and discharge emissions that could be avoided in the first place. Or why we still pay for things we will only throw away.

Wills encouraged the audience to think of “seven green wastes”: energy, water, materials, garbage, transportation, emissions and biodiversity. Wills identified each of these areas as being rich in simple opportunities to target efficiency gains. For example, efficiency opportunities on the energy front could be as easy as sealing air compressor leaks. When thinking about biodiversity and energy efficiency, Wills said manufacturers could cover exteriors of buildings with plants to form green walls that offer cooling benefits.

This lean mindset was summed up by presenter Jim Farmer, a trainer in lean manufacturing and P2 (pollution prevention) implementation. “Lean is a production practice that considers expending resources for any goal other than creating value for customers to be wasteful and a target for elimination.”

Farmer pulled the audience into the world of lean with an interactive exercise. The audience was divided into 12 teams of about five people each. A sample plant diagram was distributed, and teams were asked to apply lean manufacturing principles as they hunted for waste.

While the teams shared some common approaches, each one delivered a unique lean plan – whether it was moving a compressor to reduce the chance of air leaks or suggesting the use of low-solvent paint to reduce the need for ventilation. Farmer was encouraged and used the responses to hammer home the point that lean opportunities are all around us.

The group exercise also supported the main thrust of David Arkell’s presentation. As President and CEO of energy services firm 360 Energy, he constantly points out that people are at the heart of energy efficiency and lean manufacturing. “We must focus on people and their ideas and hold them accountable. Technology on its own won’t do the job.”

Arkell says going lean and green means you have to have a SMART plan – Specific, Measurable, Accountable, Realistic and Time Bound. He is also a big proponent of emphasizing the cumulative nature of energy efficiency and other green initiatives to show their true benefit.

When it comes to showing the benefit of being lean and green, presenter Peter Corbyn encouraged participants to keep an eye out for a tool he is developing for the Automotive Parts Manufacturers’ Association (APMA) with funding from NRCan. Corbyn, a lean trainer and co-founder of the environmental hub GreenNexxus.com, is developing a secure Web site that will include:

  • an energy and carbon calculator so participants can calculate their greenhouse gas emissions
  • a tool to track cumulative energy costs and greenhouse emissions that will be available in real-time
  • an energy-savings calculator to help estimate cost savings of various projects
  • a mechanism for participants to post real-time case studies and share information and data

The workshop ended with the presenters all repeating the mantra that green is good for the bottom line. “Going green will strengthen Canadian industry and manufacturing as a whole,” Wills said.

Back to top.

Energy management information systems make energy visible and create value

State-of-the-art energy management information systems (EMIS) are giving new life to the old adage “you can’t manage what you can’t measure.” More than 50 people attended the Energy 2009 conference workshop entitled EMIS: Energy Management for Sustained Benefits to learn more about how to transform energy data into energy performance information.

“With EMIS you can make energy performance visible for key people in your organization. Then you can make decisions and create financial value,” said co-presenter Peter Bassett, President of Energy Performance Services. “Creating financial value is key to advancing energy efficiency projects.”

EMIS converts energy and utility data into energy performance information using performance equations that are compared with dynamic energy targets. This dynamism means targets can adapt to changing circumstances. EMIS can be characterized as a dashboard view of an organization’s energy use.

“What we’re seeing is industry making the link between information technology and energy efficiency to get the right information in order to make the right decisions,” said co-presenter Mike Bujold, Director of Commercial and Industrial Sectors at Efficiency New Brunswick.

New Brunswick has made big strides in rolling out EMIS projects. The Efficiency New Brunswick program has 24 participants with 23 completed EMIS audits, the first stage of the process. Five participants are developing EMIS implementation plans. One is embedding EMIS into existing processes. And Flakeboard, a New Brunswick wood products maker, is at the commissioning stage. Bujold is confident that the vast majority of program participants are on track to implementing an EMIS.

Using its EMIS, Flakeboard is tracking the real-time effect of mechanical equipment changes on energy consumption. This allows the company to make timely adjustments to improve product quality and reduce energy consumption. “You can’t realize the full potential of an energy management project without completely integrating and configuring an energy management system,” said Pat Burke, Electrical Systems Coordinator at Flakeboard and a presenter at the workshop.

In response to audience questions about the best way to implement EMIS, Burke and the other presenters emphasized three key elements: people, management systems and technology. All three need to be onside and up to the task before an EMIS can be implemented effectively.

EMIS doesn’t save money by itself. People do. It’s really about leveraging human intelligence and information technology,” Bassett concluded.

Back to top.

What’s New

ecoENERGY Retrofit Incentive for Industry – Program Update

ecoENERGY Retrofit Incentive for Industry provides a financial incentive of up to 25 percent of project costs to a maximum of $50,000 to help companies implement retrofit projects that generate annual energy savings and pay for themselves through reduced expenditures on utilities, such as energy, water and waste.

Effective December 2, 2009, industrial clients who have already successfully completed a retrofit project are no longer required to wait 12 months before applying for a second project at the same facility.

A single facility can apply for more than one retrofit incentive to a maximum of $50,000 per application provided the previous project has been completed. A company with more than one facility can apply for more than one incentive provided that each application is for a different facility. The corporate maximum over the five-year life of the program is $250,000.

On-Line Directory of Energy Efficiency and Alternative-Energy Programs in Canada

NRCan’s Office of Energy Efficiency (OEE) maintains the on-line directory of programs to promote the efficient use or conservation of energy at the end-use level and/or the use of alternative energy in Canada. It covers programs offered by the Government of Canada, provincial and territorial governments, major Canadian municipalities, major electric and gas utility companies, and other program providers. For each program, it provides a brief description of objectives, targeted sectors and sub-sectors, program delivery tools, eligibility criteria for funding and contact information.

For more information, visit oee.nrcan.gc.ca/corporate/statistics/neud/dpa/policy_e/programs.cfm.

Back to top.

New CIPEC Leaderscompanies that that have joined from November 1 to 30, 2009

Chemicals Sector
Germiphene Corporation – Brantford

Electrical and Electronics Sector
Duke Electric Ltd. – Hamilton

Fertilizer Sector
Sherritt International Corporation – Fort Saskatchewan

Food and Beverage Sector
Belgian Nursery Limited – Breslau
Johnston Greenhouses & Garden Centre – Peterborough
Les Serres du Marais, Inc. – Ste-Martine
Parkway Gardens Ltd. – London
Select Food Products Limited – Toronto
Sovereign Farms – Waterford
Windset Greenhouses Ltd. – Delta

General Manufacturing Sector
BRC Business Enterprises Ltd. – Georgetown
Byers Bush Inc. – Mississauga
DCR Holdings Inc. – Stoney Creek
Laser Impressions Inc. – Saskatoon
Saint-Gobain Ceramic Materials Canada Inc. – Paris
Soudure Germain Lessard Inc. – Boucherville
Tri-Service Metal Products Inc. – Ajax
Unimotion-Gear – Division of Magna Powertrain Inc. – Aurora

Mining Sector
Les Tourbières Berger Ltée
– Baie Sainte Anne
– Baie-du-Vin

Plastics Sector
Kohler Canada Co. – Armstrong
Papp Plastics & Distributing Limited – Windsor
S & Q Plastic – Division of Uniglobe (Canada) Inc. – Mississauga

Pulp and Paper Sector
Easy Pack Corporation – Markham
Industries Ling inc. – Warwick

Steel Sector
Armtec Limited Partnership
– Guelph
– Orangeville
– Woodstock

Transportation Equipment Manufacturing Sector
Summo Steel Corp. – Burlington

Back to top.

Dollars to $ense energy management workshops – Schedule for January and February 2010

Legend
SPOT: Spot the Energy Savings Opportunities
EM: Energy Monitoring
EMP: Energy Management Planning
EEF: Energy Efficiency Financing

Calgary, AB
SPOT – January 20
EM – January 21

Regina, SK
EMP – January 12
EEF – January 13

Toronto, ON
SPOT – January 18
EM – January 19
EMP – February 2
EEF – February 4

Ottawa, ON
EEF – January 20
EMP – February 4

Montreal, QC
SPOT – January 20
EM – January 21
SPOT – February 17
EM – February 18

Halifax, NS
SPOT – January 27, 2010
EM – January 28, 2010

To register, visit oeeforms.nrcan.gc.ca/index-eng.cfm?event=dollars-sense-registration.

Workshop winter/spring 2010 schedule

Calendar of Events

Back to top.

Call for story ideas

Has your company implemented successful energy efficiency measures that you would like to share with Heads Up CIPEC readers? Please send your story ideas for consideration to Jocelyne Rouleau by e-mail at jocelyne.rouleau@nrcan.gc.ca.

If you require more information on an article or a program, contact Jocelyne Rouleau at the above e-mail address.

Back to top.