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Joe Feskanin – Team Leader
Elkin Mejia – Lehigh Intern
Himanshu Katiyar– Lehigh Intern
ESC Team
Introduction
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Objectives
1. Overview of Power Reduction Opportunities
2. To develop an open relationship between Nestle and the ESC
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• The plants produce Nestle Pure Life and Deer Park water• Produce about 5 million bottles of water a day• They ship out typically 500 trucks a day• Energy costs are approximately $300,000 a month for each plant
• Newer plant intends on installing three more lines along with all additional support equipment needed• Newer plant will also install two to four additional injection molders• Will create room for up to an additional 100 employees in newer plant
Current Plants
Future Plans
Nestle Waters Background
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Project Goals
• Create Flow diagrams of plants’ energy distribution for Nestle Waters to use as training tools for employees
• Find the breakdown of kWh a month among the plants’ major equipment categories/Pareto analysis
• Find ways for Nestle Waters to cut energy costs before 2010
• Compare the energy consumption between their new plant vs. a second old plant and locate the gaps between them
• Research feasibility of alternative energy sources
New Power Distribution Block Diagram: Plant I
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Results: Plant I
Energy Consumption vs. Equipment (Percentage Distribution)
5,80415,31021,30337,18737,652
225,330255,660
390,820
535,323
642,079
0
100,000
200,000
300,000
400,000
500,000
600,000
700,000
800,000
900,000
1,000,000
Equipment
kWh
50.8% (3)
49.2% (4)
770,389
50.8% (2)
49.2% (1)
617,888
49.6% (2)
144,691
50.4% (1) 21.4% (1)
20.7% (2)
20.7% (3)
18.3% (4)
864,998
18.9% (5)
19.5% (1)
19.5% (2)
19.5% (3)
23.7% (8)
17.8% (9)
Equipment energy consumption (kWh) (Calculations are based on 5 lines running at full production for 29 service days at $.068/ kWh).
New Power Distribution Block Diagram: Plant II
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Estimated Results: Plant II
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Equipment energy consumption (kWh) (Calculations are based on production for 29 service days at $.068/ kWh).
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Discussion
