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Kevin Chilcoat Frito-Lay/PepsiCo [email protected] (972) 334 4890 U.S. DOE Industrial Distributed Energy Portfolio Review Meeting Washington, D.C. June 1-2, 2011 CHP for Food Processing Frito-Lay Killingly CT.

CHP for Food Processing - Department of EnergyCHP for Food Processing Subject Presentation on CHP for Food Processing, given by Kevin Chilcoat at the U.S. DOE Industrial Distributed

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Page 1: CHP for Food Processing - Department of EnergyCHP for Food Processing Subject Presentation on CHP for Food Processing, given by Kevin Chilcoat at the U.S. DOE Industrial Distributed

Kevin Chilcoat Frito-Lay/[email protected]

(972) 334 4890

U.S. DOE Industrial Distributed Energy Portfolio Review Meeting Washington, D.C.

June 1-2, 2011

CHP for Food Processing

Frito-Lay Killingly CT.

Page 2: CHP for Food Processing - Department of EnergyCHP for Food Processing Subject Presentation on CHP for Food Processing, given by Kevin Chilcoat at the U.S. DOE Industrial Distributed

2

We’re More Than Just Pepsi Cola

Global Presence19 - Billion Dollar Brands$58 Billion in Revenue300,000 Employees

Global Distribution100,000 Sales RoutesBusinesses in Virtually

EveryCountry in the WorldLargest Markets: USA,Russia, Mexico

High VisibilityWaterEnergy and GHGLand Fill

PepsiCo’s Billion Dollar Brands

Presenter
Presentation Notes
PepsiCo has 19 mega-brands that generate $1 billion or more each in annual retail sales. All have great and steadily improving brand equity in the eyes of consumers – they are trusted, they are loved, they stand for high quality, safety and great taste. What is so incredible is how quickly this billion dollar club has grown – we have gone from 6 billion dollar plus brands in 1990 to 11 in 2000 to 19 today. [RIGHT CHART WILL APPEAR] And, we have many more very large brands in our global portfolio – for example brand Wild Cherry Pepsi has over $500MM in retail sales. With this is incredible portfolio of brands, we are the second largest Food & Beverage business in the world and, across the total consumer space, PepsiCo is the third largest CPG business in the world. And we are the largest Food & Beverage business in North America and the largest CPG business overall in North America. This is a tremendous position of strength to start from, but we believe we have more than size in our favor.
Page 3: CHP for Food Processing - Department of EnergyCHP for Food Processing Subject Presentation on CHP for Food Processing, given by Kevin Chilcoat at the U.S. DOE Industrial Distributed

3

PepsiCo has Incredible Products

Page 4: CHP for Food Processing - Department of EnergyCHP for Food Processing Subject Presentation on CHP for Food Processing, given by Kevin Chilcoat at the U.S. DOE Industrial Distributed

4

Performance with Purpose

Be Responsible Steward of Our

Planet’s Resources

Attract, Retainand Develop

World-Class Talent

Nourish Consumers with a Range of

Products

Page 5: CHP for Food Processing - Department of EnergyCHP for Food Processing Subject Presentation on CHP for Food Processing, given by Kevin Chilcoat at the U.S. DOE Industrial Distributed

In support of the Environment Plank…..Killingly CHP Project

Solar Centaur 50

4.6 MW

Natural Gas

Turbine/Generator

HRSG / Duct Burner

100% of Plant’s Electric Needs

80% of Plant’s Thermal Needs

Page 6: CHP for Food Processing - Department of EnergyCHP for Food Processing Subject Presentation on CHP for Food Processing, given by Kevin Chilcoat at the U.S. DOE Industrial Distributed

Killingly CHP Project

Page 7: CHP for Food Processing - Department of EnergyCHP for Food Processing Subject Presentation on CHP for Food Processing, given by Kevin Chilcoat at the U.S. DOE Industrial Distributed

Project Objective

What are you trying to do? Reduce operating costs ( total energy costs )

What is the problem? High electric rates and excessive electric grid congestion

Why is it difficult? Need the right combination of:

Electric Rates Incentives Fuel Prices On-site Technical Competencies Electric Load Legislative Support Thermal Load Utility Support

Page 8: CHP for Food Processing - Department of EnergyCHP for Food Processing Subject Presentation on CHP for Food Processing, given by Kevin Chilcoat at the U.S. DOE Industrial Distributed

State of the Art - Before

Primary Electric Loads• Process Motors• Air Compressors

Primary Steam Loads• Fryer Oil Heating• Water Heating

Page 9: CHP for Food Processing - Department of EnergyCHP for Food Processing Subject Presentation on CHP for Food Processing, given by Kevin Chilcoat at the U.S. DOE Industrial Distributed

State of the Art - After

Electric Steam

Steam

Page 10: CHP for Food Processing - Department of EnergyCHP for Food Processing Subject Presentation on CHP for Food Processing, given by Kevin Chilcoat at the U.S. DOE Industrial Distributed

Low Nox Performance

Parallel to Grid – Load Following

Proven Highly Reliable Turbine / Generator Package

Combined with Site Reliability Strategy

Unique Project Structure – Strong Team

Unleashed Future Plant Capabilities

Technical Approach

Page 11: CHP for Food Processing - Department of EnergyCHP for Food Processing Subject Presentation on CHP for Food Processing, given by Kevin Chilcoat at the U.S. DOE Industrial Distributed

Project Team Approach….Reduced Costs

Dana TechnologyPrelim Eng.

JCK EngineeringInterconnect

CPL SystemsControls / Inst.

Waldren Eng.Detailed Design

Construction

Frito Lay

Page 12: CHP for Food Processing - Department of EnergyCHP for Food Processing Subject Presentation on CHP for Food Processing, given by Kevin Chilcoat at the U.S. DOE Industrial Distributed

Project Approach Preliminary Engineering

Frito-Lay, Inc. Dana Technologies – Jim Leach, President

Long Lead Equipment Purchase Frito-Lay, Inc

Detailed Engineering & Construction Waldron Engineering & Construction, Inc.

Project Manager – Mark Letourneau

Instrumentation & Controls CPL Systems, Inc

Project Manager – Jack Hodges

Utility Interconnect/Switchgear Design/Fabrication JCK Engineers, Inc. – James Kuhn, President

Page 13: CHP for Food Processing - Department of EnergyCHP for Food Processing Subject Presentation on CHP for Food Processing, given by Kevin Chilcoat at the U.S. DOE Industrial Distributed

Equipment - $6MM Installation - $4MM Building - $1.0MM Engineering - $1.0MM Total - $12MM

State of Connecticut Grant - $1.7MM Investment Tax Credit – 10% (not in project economics)

Additional BenefitsClass III REC’s Lower NG Prices

Project Budget

Page 14: CHP for Food Processing - Department of EnergyCHP for Food Processing Subject Presentation on CHP for Food Processing, given by Kevin Chilcoat at the U.S. DOE Industrial Distributed

Project Development 01/06 – 12/06

State Grant Application/Award 03/06 – 08/06

Preliminary Engineering 06/06 – 06/07

Project Funding Approval 02/07

Purchase Long Lead Equipment 03/07 – 06/07

Permitting – Air & Construction 05/08

Engineering/Procurement/Construction 02/08 – 03/09

Commissioning 03/09

Emission Testing 08/09

Project Schedule Milestones

Main Take-Away:

It’s Not Easy or Quick

Page 15: CHP for Food Processing - Department of EnergyCHP for Food Processing Subject Presentation on CHP for Food Processing, given by Kevin Chilcoat at the U.S. DOE Industrial Distributed

Benefits

0

5000000

10000000

15000000

20000000

25000000

kWh

Before

After

34000

36000

38000

40000

42000

44000

46000

Mtons

Before

After

0

100000

200000

300000

400000

500000

600000

700000

800000

MMBTU's

Before

After

Electric = 94% Reduction

N. Gas = 25% Increase

GHG = 15% Reduction

Page 16: CHP for Food Processing - Department of EnergyCHP for Food Processing Subject Presentation on CHP for Food Processing, given by Kevin Chilcoat at the U.S. DOE Industrial Distributed

Questions?

Kevin Chilcoat Frito-Lay/PepsiCo

[email protected]

(972) 334 4890