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CIPEC Heads Up

Industry calendar of events

Heads Up CIPEC


November 15, 2011 Vol. XV, No. 14


Articles

REMINDER: Energy 2011 Conference – PepsiCo Frito Lay Canada’s Helmi Ansari and Pulse Energy’s David Helliwell will share their experiences at Energy 2011 luncheons

Delegates at the Energy 2011 conference in Toronto this month will have the opportunity to hear from Helmi Ansari, PepsiCo Frito Lay Canada’s Director of Sustainability and Productivity about his company’s efforts, successes and challenges in the area of environmental sustainability. David Helliwell, Co-founder of Pulse Energy, a Canadian developer of energy management software, will share his expertise in energy management systems.

Ansari, who has worked in the manufacturing supply chain industry (including a dozen food and pharmaceutical manufacturing plants) all across North America, says that Energy 2011 will be an important meeting. “In economic times like these, it is critical to bring influential people together to validate and share how we can continue with and accelerate reducing our environmental footprint.”

Ansari, a mechanical engineering graduate who holds an MBA and is currently a PhD candidate in business/sustainability with the TUM School of Business in Germany, has spent the past 14 years at PepsiCo leading productivity initiatives and evolving the company’s environmental vision. He is primarily responsible for leading the company’s agenda on environmental sustainability, strategic financial planning, annual operating and productivity plan development and continuous improvement for operations.

“I would like to share my experience and open the door for an exchange,” says Ansari, indicating that he plans to talk about PepsiCo’s journey in environmental sustainability and the company’s current initiatives in this area. He notes that even with limited capital input, companies can still be innovative in terms of energy efficiency.

Helliwell, who has been working in the energy sector since 1994, says, “There are so many opportunities to improve the bottom line while simultaneously addressing environmental sustainability and energy efficiency.” During his career as a Paris-based consultant to large multinational organizations and as the director of policy for the Canadian Minister of Public Works and Government Services, he has gathered significant experience in energy management.

Having been responsible for reducing costs and improving the environmental performance of 700 million square feet of office space across the country, Helliwell knows that companies “can make painless change that has a major impact on efficiency. Helliwell co-founded Pulse Energy five years ago – a company that analyzes and communicates energy information to facility managers. Helliwell also uses his experience as the current director of the Vancouver Board of Trade, an Action Canada Fellow, a member of the BC Cleantech CEO Alliance, and as an advisory board member of Imagine BC.

Don’t miss this great opportunity to hear Helmi Ansari and David Helliwell speak about their experiences and vision in pushing the sustainability envelope forward at Energy 2011.

To register, visit www.energy2011.ca/english/attendees/registration.html.

For more information, visit www.energy2011.ca/.

Helmi Ansari
Helmi Ansari, Director of Sustainability and Productivity, PepsiCo Frito Lay Canada
David Helliwell
David Helliwell, Co-founder, Pulse Energy

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NRCan funding is available for implementation of ISO 50001 Standard pilot projects

Implementation of the ISO 50001 Standard for Energy Management Systems has just become easier because a new suite of funding is available from Natural Resources Canada’s (NRCan’s) ecoENERGY Efficiency for Industry program. The funding program is designed to help industrial companies of all types and sizes comply with the new standard by establishing the groundwork necessary to take a systematic approach to continually improving energy performance.

NRCan’s ecoENERGY Efficiency for Industry program will provide financial assistance of up to 50 percent of costs, to a maximum of $25,000, for ISO implementation pilots, process integration (PI) studies and computational fluid dynamics (CFD) studies. While funding for ISO implementation pilots specifically aims to support industrial facilities in preparation for certification, financial assistance for both the PI and CFD studies will prepare companies for the implementation of energy management systems (EMS), in eventual support of ISO certification.

Incentives for ISO 50001 implementation pilots can help cover professional fees, training, gap analysis (e.g. EMIS audit), as well as energy assessments. Funding can also be put toward an energy management information system (EMIS) audit. An EMIS audit is a crucial step to implementing an EMIS because it makes energy visible to all levels of an organization, enabling individuals and departments to systematically plan, make decisions and take effective action to manage energy use and costs. An EMIS, by definition, has a systematic approach already embedded in it. Companies can directly use it to help with their compliance to ISO 50001.

Pilot implementations of the ISO standard should lead to reductions in energy costs, greenhouse gas emissions and other environmental impacts. However, the primary goal of an implementation is to enable an organization to establish systems and processes to take a systematic approach to achieve continual improvement.

Eligibility for the pilot funding is contingent on the participation of employees or consultants who have experience with energy management standards such as ISO and ANSI. Participating companies are required to report the measures undertaken to meet ISO 50001; they must also commit to monitor and report on results for a given period of time.

Organizations that have a longer way to go before reaching a certification-ready status will also benefit from NRCan’s ecoENERGY Efficiency for Industry program. CFD studies aim to identify the most efficient design and operational parameters with respect to fluid flow and heat transfer. In preparation for ISO implementation, the CFD Study incentive will help reduce the cost of hiring a technical firm to conduct the necessary assessments to achieve process optimization and emission reductions.

Similarly, the Process Integration Study incentive will also offset the expense associated with hiring consultants to perform assessments. A PI study analyses the most efficient use of energy, water and raw materials in industrial facilities. It takes a whole system approach to energy management by identifying and optimizing interactions between systems in large and complex industrial facilities. Similar to an EMIS audit, a PI study provides valuable information to decision makers about how energy is being used and where improvements can be made.

Organizations that conduct a PI study in their facilities will be one step closer to complying with the ISO standard. For both the PI and CFD study incentives, companies must submit an energy intensity improvement plan with their final report, outlining the general requirements of an EMS, including energy performance improvement targets, the projects to be implemented, their associated savings, the implementation timeline, as well as monitoring and reporting of results. To be eligible for any of the incentives, a company must have its technical proposal approved by NRCan before the start of the project.

For more information about NRCan’s ecoENERGY Efficiency for Industry program, visit oee.nrcan.gc.ca/industrial/financial-assistance/assessment/index.cfm or contact info.ind@nrcan-rncan.gc.ca.

A copy of the ISO 50001 Standard for Energy Management Systems can be purchased from the Canadian Standards Association at shop.csa.ca/en/canada/energy-efficiency/cancsa-iso-5000111/invt/27032662011.

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Energy efficiency – Baxter Canada’s way of doing business

“We see energy efficiency as strategically important. It’s been integrated into our operations for a long time,” comments John Eley, Plant Manager at Baxter Corporation’s facility in Alliston, Ontario. This integration has led to significant energy savings over the past few years with a 6 percent reduction in energy use in 2010, up from 3 percent in 2009.

The Alliston facility, a CIPEC Leader in the General Manufacturing Sector, produces life-sustaining intravenous, nutritional, peritoneal dialysis and hemodialysis solutions. The 16 700 square-metre (m2) plant employs more than 400 people and operates 24 hours (hr) a day, 5 days a week for 50 weeks a year.

Eley explains that energy efficiency efforts are part of the facility’s lean energy program, which defines levels of achievement, each with specific requirements and guidelines. Baxter Corporation also benchmarks within the company and externally to determine best practices. The company holds a bi-annual internal energy conference allowing employees to learn from each other and from experts in the energy field.

“Our facility has a cross-functional energy team, which generates many project ideas. We also have a suggestion program and leverage the facility’s 6S Excellence Award Program for employees, which integrates energy conservation and energy efficiency training,” says Eley.

Using 2005 as its baseline year, Eley explains that, to date, the Alliston facility has reduced its natural gas and electricity use by 30 percent and water consumption by 56 percent. Eley attributes some of these savings to the installation of heat exchangers that capture heat from the boiler stacks to preheat incoming, cool sterilization water needed for product steam sterilization. In the winter, 7°C water can be preheated to 54°C. “We are working to increase this to 74°C to further increase our savings,” he notes.

The facility also requires high purity water for its products and has recently retrofitted the compressors on its distillation units with variable frequency drives. Most of the facility’s metal halide, magnetic ballast lighting has been replaced with T-5 lamps on electronic ballasts with occupancy sensors. “This alone has saved us 7 percent on our electrical bill annually.” Eley adds.

Other improvements include quarterly boiler tune ups, installing boiler control systems that monitor oxygen content, and optimizing sterilization cycles. “In some cases, we have been able to increase sterilization throughput by 30 percent, significantly reducing natural gas consumption,” says Eley.

Steam from the sterilization process is now re-circulated rather than vented to the atmosphere. A compressed air reservoir has been added to deliver air to equipment throughout the plant at a constant pressure of 95 pounds per square inch. Additionally, all heating, ventilating and air-conditioning equipment motors have been retrofitted with variable frequency drives.

Several projects have already been identified for 2012, including leveraging the heat reclaim system and optimizing heat recovery to deliver a constant temperature to the distillation units. Eley is always on the lookout for simple, low capital-cost projects. “It all adds up, and everyone can participate in energy efficiency – that’s our attitude.”

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According to the ICE survey, energy use and intensity in the manufacturing sector followed economic trends in 2009

The Industrial Consumption of Energy (ICE) Survey – Summary Report of Energy Use in the Canadian Manufacturing Sector, 1995–2009, co-sponsored by Natural Resources Canada’s (NRCan’s) Office of Energy Efficiency (OEE) and Environment Canada, was released in July 2011. The survey is an essential tool for monitoring the energy consumption by manufacturing industries and helps support the OEE’s mandate to strengthen and expand Canada’s commitment to energy conservation and energy efficiency.

Analysis of 2009 data found that Canadian manufacturing industries accounted for the largest share of energy use – 65.9 percent – in the industrial sector, representing 29.3 percent of total secondary energy use in the country.

Within the manufacturing sector, four subsectors – Paper Manufacturing (NAICS 322), Primary Metal Manufacturing (NAICS 331), Petroleum and Coal Product Manufacturing (NAICS 324) and Chemical Manufacturing (NAICS 325) – contributed to 76 percent of all energy consumption in the same year. Between 1995 and 2009, overall energy consumption declined by nearly 18 percent or 445 petajoules for the paper, primary metal, petroleum and coal product and chemical industries. The largest decline in both energy consumption and intensity, 41.4 and 27.4 percent, was in the paper sector, which also experienced a decline in GDP during the same period.

Given the continued impact of the economic downturn during 2009, almost every manufacturing subsector experienced decreased output and energy use with a resulting increase in energy intensity because output declined faster than energy use. The petroleum and coal products sector was the only exception, reporting a decrease in energy intensity from 2008 to 2009.

The ICE survey notes that despite lower capacity utilization rates for most of the manufacturing subsectors in 2009, the third quarter of 2009 shows that 15 of 21 subsectors posted gains in those rates.

To read the full report, visit oee.nrcan.gc.ca/publications/statistics/ice09/index.cfm.

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Thermal pump eliminates heating costs at La Fromagerie Polyethnique

“The integration of new CO2, supercritical, thermal pump technology into our processes is revolutionary and now opens the door to other applications within the plant,” says Alain Marchand, Director of Operations at La Fromagerie Polyethnique inc. Marchand is referring to the company’s recent installation of a Japanese-made thermal pump – EcoCute, which is supplying all of the facility’s hot water needs.

La Fromagerie Polyethnique inc., a CIPEC Leader in the Dairy Sector, produces specialty Mediterranean cheeses in its 3345-m2 facility in Saint-Robert, Quebec. The company employs approximately 30 people who work in 8-hr shifts, year-round.

Marchand explains that energy efficiency has always been integral to the company’s mission; that commitment is also why the company is willing to take risks on new energy-efficient technology and on projects with longer payback periods. “We invested $1.3 million in the EcoCute technology because we want to do things right by integrating our heating and cooling processes,” says Marchand.

La Fromagerie Polyethnique consumes 9 million litres (L) of hot water annually for washing operations including clean-in-place (CIP), and numerous washes and rinses that are integral to their cheese-making process. Marchand notes that the plant’s hot water needs used to be supplied by gas-fired steam boilers.

To adapt the technology in Canada, La Fromagerie Polyethnique is using the 12-tonne (t) EcoCute thermal pump to serve its heating and cooling needs simultaneously, including the plant’s two CIP systems, a washing tunnel for cheese moulds, a hot water bath for Halloumi cheese and for 11 manual hot water wash stations.

The EcoCute, which uses carbon dioxide (CO2) in the super critical phase, also supplies more than 65 percent of the facility’s refrigeration needs in conjunction with a cold storage reservoir – Cristopia, a new technology from France. The reservoir holds spherical nodules that are filled with phase-change material made of a blend of polyolefin. The system allows the cooling of two blast cooler product tunnels and a constant temperature in two cold storage chambers in three process tanks and various systems that can accommodate up to 80 000 L of milk at 2°C.

With the new technology, incoming 10°C water is heated to 90°C by using only 21 kilowatt hours (kWh) while generating 43 kWh of cooling power and 65 kWh of heat. “The energy gains are incredible,” notes Marchand.

The integration of heating and cooling processes not only stores and recuperates energy but also keeps the facility’s temperature ambient. Marchand notes that the EcoCute also allows the existing thermal pumps to operate within an optimal temperature range. “We now have a system that keeps water at a constant temperature in a closed circuit system that feeds the thermal pumps that either push warm or cool water through the system depending on the season,” says Marchand.

All thermal pumps – four dedicated to heating and cooling the facility and two to process heating and cooling – function in conjunction with heat exchangers that capture waste heat from various equipment and processes including air compressors, lactoserum production, and pre-heating wash water.

Marchand indicates that, prior to integrating its heating/cooling water processes, La Fromagerie Polyethnique had initiated several projects, including roof solar pre-heating chambers that allow cold air to be heated to up to 10°C and a wind break planted in the 1980s, as well as a lighting retrofit for more efficient lamps and fixtures.

La Fromagerie Polyethnique no longer needs to heat any of its process water with a propane furnace. With its integrated technology the company is not only saving heating costs but also diverting 156 t CO2 equivalent annually. “We have reached our goal; we want to be leaders in innovation and efficiency,” concludes Marchand, noting the company’s willingness to share their expertise, project ideas and lessons learned.

La Fromagerie Polyethnique

La Fromagerie Polyethnique is using the 12-tonne (t) EcoCute thermal pump to serve its heating and cooling needs. (chart available in French only)

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Dollars to $ense Energy Management workshops

Dollars to $ense Energy Management workshops – Schedule for December 2011 and January and February 2012

Legend
EEF: Energy Efficiency Financing
EM: Energy Monitoring
EMP: Energy Management Planning
SPOT: Spot the Energy Savings Opportunities
EMIS: Energy Management Information Systems
RCx: Recommissioning

(F) = French

Toronto, Ont.
SPOT – January 26
EMIS – February 7
EM – February 16

Montréal, Que.
RCx – February 23 (F)

Québec, Que.
EMP – February 8 (F)

Fredericton, N.B.
EEF – December 1

Halifax, N.S.
EMIS – January 24
EEF – January 31
SPOT – February 22
EM – February 23

Workshop schedule and registration – fall 2011 to spring 2012

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New CIPEC Leaderscompanies that joined from October 1 to 31, 2011

Chemicals Sector
Sanofi Pasteur Limited – North York, Ont.

General Manufacturing Sector
Crown Metal Packaging Canada LP – Calgary, Alberta

Pulp and Paper Sector
AbitibiBowater Inc. – Division La Doré – La Doré, Qué.

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Upcoming events

For a complete list of industrial program events, visit oee.nrcan.gc.ca/industrial/opportunities/calendar/index.cfm.

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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.

You can also use the subscribe page to change your contact information, to unsubscribe or to subscribe to Heads Up Energy Efficiency, our sister publication for commercial, institutional and federal government buildings. If you are experiencing difficulty accessing the subscription page, see our help section, call 613-996-6891 or send an e-mail to info.ind@nrcan-rncan.gc.ca.

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