Reducing Kilowatts - · PDF fileSysco Case Study 100+ food distribution centers (DCs) •...

Reducing Kilowatts

300,000 Foot View

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)

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

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

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

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

Year to Year Performance kW

Total Broadline Energy Intensity

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

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

Eye Level View

Lighting

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

The Right Light

Fluorescent

LED HID

The Right Light

Randy Fletcher VP Logistics & Supply Chain Management

Fluorescent

The Right Light Energy Savings?

Lumen Output?

Instant On/Off?

Optical Control?

Long Life?

Low Maintenance?

Large Utility Incentives?

Fixture Location: spacing & height

Desired Light Levels

The Right Place

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

The Right Time

Occupancy Sensors & Timers in

Offices

Bryan Genevick, Project Engineer-Mechanical

Advocates Coaches Existing Vendors

Beneath the Surface

Mechanical

VFD Energy Savings

Avg. % Speed Reduction

Potential Energy Savings

10% 22%

50% 83%

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

Cogeneration

Chris Covell ccovell@smartwattinc.com

Bryan Genevick

bgenevick@smartwattinc.com

Marcus Wilcox Marcus.Wilcox@cascadeenergy.com

Reducing Kilowatts - · PDF fileSysco Case Study 100+ food distribution centers (DCs) •...

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