Business and Industrial Case Studies

IndustrialCase Studies

Toronto Hydro

Tyco Safety Products manufactures leading edge Digital Security Controls (DSC) branded electronic intrusion alarm products in its 188,000 square foot facility on Bridgeland Avenue. This is a true Canadian success story with over 700 employees manufacturing sophisticated systems that are shipped to over 140 countries.

Glen Brislan, Vice-President, Supply Chain praises his workforce for their ability to continually improve the quality of their products, squeeze out costs, meet stringent on-time delivery dates and be flexible to meet the manufacturing requirements to deliver over 500 different products from one location.

“We are very competitive in a global manufacturing environment,” says Brislan. “And we look to every opportunity to find efficiencies, and that includes our physical plant. That’s why Toronto Hydro’s RETROFIT PROGRAM made so much sense for us.”

above: Glen Brislan and Rexford Yirenkyitop right: Glen Brislan

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For bUSiNeSS

Tyco Safety Products

project StatiSticS

188,000 sq. ft. manufacturing and shipping facility for security products

before: 804 T-12 fluorescents and 92 360W high metallic fixtures with inefficient ballasts

after: 804 T-8 fluorescents and 92 200W metal halide fixtures with high efficiency ballasts and reflectors

project cost: $216,717

Simple payback after incentive: Approx. 1.8 years

return on investment (roi): Approx. 46.1%

electricity savings: 66% of lighting consumption

CASE STudy

February 2012

Shine a light on savings: Tyco retrofit delivers ROI of 46% with 1.8 year payback

“it took toronto hydro less than two weeks to approve our project.”

Rexford Yirenkyi, Maintenance and Facilities Manager, was given the task to look into the Toronto Hydro RETROFIT PROGRAM. Yirenkyi is no stranger to these types of efficiency initiatives. “We already have occupancy sensors in meeting rooms and washrooms, we’re very efficient at recycling and we’ve eliminated a lot of cardboard by using recyclable totes. So I was keen to explore the RETROFIT PROGRAM.”

After defining the scope of the project with Ed Alexander of Progressive Lighting, Energy & Design who designed the lighting retrofit and supplied materials, Yirenkyi submitted a RETROFIT PROGRAM application to Toronto Hydro. In under two weeks, the project was approved. Implementation (by Gemini Group Electrical Systems Inc.) took eight weeks with minimal disruption. Within a week of job completion, Toronto Hydro was back to inspect the project and provide final sign-off for the incentive.

excellent employee feedback

For Tyco, an added bonus was the spontaneous and positive feedback from employees. Says Brislan, “We knew they would notice the difference in brightness and we were very happy to hear all of their comments. We have a good relationship with employees here, and this added to it. The new lighting is good for everyone.” The old fluorescent T-12 system provided 37 foot candles of light, while the new T-8 fluorescent system delivers 54 foot candles. That’s nearly 46 per cent brighter in most areas.

the co2 reduction story in trees and cars

To really bring home the environmental benefits of this project, Tyco’s contractor noted that the net effect of this project reduces CO2 emissions from electricity generation by 137.48 tons. That is the equivalent of planting 30 full size trees or taking 30 cars off the road in one year.

More energy saving programs on the way – peaksaver® is next

Tyco is now looking for further opportunities to save. Next to be

implemented is peaksaver® on the 20 roof-top air conditioners. Says Yirenkyi,

“While we appreciate the credit we’ll get on our bill, peaksaver is more about being a good corporate citizen and helping the environment.”

“We are proud that we are good corporate citizens. We value the many environmental benefits that the RETROFIT PROGRAM delivers.”

Rexford Yirenkyi, Maintenance and Facilities Manager

Visit torontohydro.com/businessfor more information or to apply online for saveONenergy programs. Or contact us today at: Tel: 416.542.3388 Fax: 416.542.2980 Email: [email protected]

Subject to additional terms and conditions found at torontohydro.com/business. Subject to change without notice. Funded by the Ontario Power Authority and offered by Toronto Hydro. This business participated in the Business Incentive Program (BIP) offered through Toronto Hydro and funded by the Ontario Power Authority. A mark of the Province of Ontario protected under Canadian trade-mark law. Used under sublicence. OMOfficial Mark of the Ontario Power Authority. Used under licence. The star design is a trade-mark of Toronto Hydro Corporation used under licence.’Toronto Hydro’ means Toronto Hydro-Electric System Limited.

toronto hydro incentive programs

Toronto Hydro offers saveONenergy programs that provide financial incentives and technical assistance to help improve your energy efficiency. With programs available for commercial, institutional, multi-residential and industrial buildings, conservation can be an attractive investment opportunity with excellent returns. Discover your best energy-saving opportunities by starting with an energy audit and then apply for the appropriate incentive programs for further funding.

ShawCor is a global energy services company that focuses on technology-based products and services for markets including petrochemical, electrical utility, communications, automotive and electronics.

The company was formed in the 1930s in south-west Ontario, and now has over 5,800 employees in over 20 countries.

On Bethridge Road in Toronto, ShawCor has two divisions known as DSG-Canusa and ShawFlex, which occupy approximately 230,000 square feet.

Here they manufacture heat-shrink products such as rubber tubing and sleeves, along with cables used for instrumentation and robotics.

For this project, the company identified two immediate opportunities for electricity savings: replacement of nine heaters that are used in creating end caps on rubber tubing and overall lighting in key areas of the plant.

Toronto Hydro worked closely with the ShawCor team including Morteza Hashemian, Process Engineering Supervisor; Lou Bacs, HSE Engineer and Robert Fuller, Plant Engineering Manager.

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FOR BUSINESS

ShawCor Ltd – DSG-Canusa

pROjEct StatIStIcS

3 end cap machines, each using 3 electric heaters running 24/5

Before: 8 kW / heater = 72 kW

after: 0.5 kW / heater = 4.5 kW



Return on investment (ROI): Approx. 95%

Electricity savings: 67.5 kW

ShawCor Ltd – ShawFlex

pROjEct StatIStIcS

Lighting for over 150,000 sq. ft. of manufacturing

Before: 162 400-Watt metal halide fixtures

after: 162 6-lamp fluorescent T-8 light fixtures



Return on investment (ROI): Approx. 77.8%

Electricity savings: 45.9 kW

CaSe StuDy

February 2012

ShawCor sees big savings and fast ROI in equipment and lighting retrofits

aBOvE: Morteza Hashemian, P.Eng.

“We knew that our equipment was a prime candidate for electrical savings.”

“In our manufacturing process, we use heaters to pinch and seal rubber tubing to create end caps. We have three machines, each with three heaters. They are always on and we knew they represented an opportunity for savings,” said Lou Bacs.

Morteza Hashemian and his team, in coordination with Bacs, replaced the nine electric resistance heaters with infrared heaters, bringing down peak demand from 72 kW to 4.5 kW, a reduction of 93.7%.

New lighting reduces the plant’s heat load

In the ShawFlex factory, ShawCor had been using 162 400-watt metal halide fixtures. Bacs and Robert Fuller realized there was a potential for savings by upgrading.

“Working with our contractors, we were able to replace the metal halide fixtures with 162 6-lamp fluorescent T-8 light fixtures,” said Fuller. “In addition to the

reduced electrical use, the new lighting is brighter and significantly reduces the heat load.”

Both kilowatt and kilowatt-hour savings were substantial. The kilowatts were reduced from 74.2 kW to 28.3 kW, a savings of 45.9 kW, while kilowatt-hours were reduced by 392,808.

the REtROFIt pROgRam works hand-in-hand with Shawcor’s code of conduct

ShawCor’s Code of Conduct commits them to conducting business in a manner that protects the environment, reduces waste and conserves resources.

By lowering electricity requirements, ShawCor helps reduce generation demand and lower peaks, both of which have positive impacts on our environment.

toronto Hydro was knowledgeable, helpful and quick to respond

The key to success of both the lighting retrofit and equipment replacement initiatives was an efficient working relationship with Toronto Hydro.

Bacs appreciated the responsiveness and help from the team at Toronto Hydro. “We worked mainly with Bill Scott. He helped us define our opportunities and made the whole process easy. We’re now looking at further ways to take advantage of the RetRoFit PRoGRam.”

“We have equipment running 24/5. The ReTRofiT PRogRam was further incentive for us to make it as energy efficient as possible.”

Lou Bacs, P.Eng., HSE Engineer


Subject to additional terms and conditions found at torontohydro.com/business. Subject to change without notice. Funded by the Ontario Power Authority and offered by Toronto Hydro. This business participated in the Business Incentive Program (BIP) offered through Toronto Hydro and funded by the Ontario Power Authority. A mark of the Province of Ontario protected under Canadian trade-mark law. Used under sublicence. OMOfficial Mark of the Ontario Power Authority. Used under licence. The star design is a trade-mark of Toronto Hydro Corporation used under licence.’Toronto Hydro’ means Toronto Hydro-Electric System Limited.

toronto Hydro Incentive programs


With approximately 1,200 of Ontario’s dairy farmers counting on them to turn milk into a variety of dairy products, Gay Lea Foods Co-operative puts a priority on keeping production lines running. So when it came to improving energy efficiency, maintaining production integrity was of vital importance. Through the assistance of suppliers and Toronto Hydro, equipment and lighting retrofits at Gay Lea’s Toronto area plants prove that implementing energy efficiencies doesn’t have to impact production. Gay Lea participated in the Business Incentive Program (BIP) funded by the Ontario Power Authority. Similar incentives can be found through saveONenergy incentive programs.

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FOR BUSINESS

Gay Lea Foods Co-operativepROjEct StatIStIcS

Lighting retrofit at two processing plants

Before: 377 metal halide and T-12 fluorescent fixtures

after: 434 lower wattage T-5 and T-8 compact fluorescent fixtures with occupancy sensors




annual electricity savings: Approx. $33,924

Replacement of fixed speed air compressor with variable speed drive air compressor

Before: 100 hp fixed speed air compressor consuming 13,000 kWh/week

after: 100 hp variable speed air compressor consuming 8,000 kWh/week




annual electricity savings: Approx. $26,000

Case study

February 2012

With energy-efficient retrofits, Gay Lea Foods whips up sustainable energy savings

aBOvE, lEFt tO RIght: Rahul Nakra, Corporate Process Engineer, Zbigniew Ewertowski, Director of Corporate Engineering

Knowledge helps yield power savings

An energy audit is the first step for any business looking to save energy. In Gay Lea’s case, audits revealed that upgrading lighting and replacing aging air compressors provided the best opportunity for realizing energy efficiencies. And, as Toronto Hydro’s Bill Scott pointed out, both were eligible for incentive programs offered through Toronto Hydro.

Matching capacity to demand

Through computer analysis, two 100 hp fixed speed air compressors were found to be providing more capacity than was currently needed, thereby wasting energy. Replacing one 20-year-old compressor with a newer, more efficient variable speed drive unit allowed Gay Lea to more accurately match capacity with demand. “Any industrial facility should be looking at variable speed drive where demand varies to help eliminate energy waste,” reports Gay Lea’s Director of Corporate Engineering, Zbigniew Ewertowski.

Improving lighting quality while saving energy

In a food processing facility, lighting must meet the Canadian Food Inspection Agency standards. Replacing older, less efficient metal halide and T-12 fixtures with energy-efficient T-5 and T-8 technology resulted in reductions in wattage while improving lighting quality. Since the newer fixtures also produce less heat, they can also lower the load on HVAC systems.

Maintaining production integrity

Both projects proceeded with minimal disruption to daily production as a result of a concerted effort by all stakeholders – equipment suppliers, Toronto Hydro and Gay Lea and its employees. As Rahul Nakra, Corporate Process Engineer at Gay Lea, points out, “Our employees really got behind these initiatives. They knew that saving energy whenever we can is simply the right thing to do.”

Encouraged by their success, Gay Lea is pushing ahead for greater energy

savings. Lighting retrofits are nearing completion at other plants and as aging equipment needs replacing, energy efficient equipment tops the list.

“proven results and a positive experience encouraged us to apply what we learned through these projects to our other facilities for additional energy savings.”

Zbigniew ewertowski, director of Corporate engineering

Subject to additional terms and conditions found at torontohydro.com/business. Subject to change without notice. Funded by the Ontario Power Authority and offered by Toronto Hydro. This business participated in the Business Incentive Program (BIP) offered through Toronto Hydro and funded by the Ontario Power Authority. Project results have been verified by Toronto Hydro. A mark of the Province of Ontario protected under Canadian trade-mark law. Used under sublicence. OMOfficial Mark of the Ontario Power Authority. Used under licence. The star design is a trade-mark of Toronto Hydro Corporation used under licence.’Toronto Hydro’ means Toronto Hydro-Electric System Limited.

toronto hydro Incentive programs



KIK Custom Products manufactures and packages household products such as sunscreens and toothpaste for many leading brands. Compressors are used throughout the facility to fill bottles and cap them.

Upon an analysis of their systems, KIK found that the fastest way to cut electricity use for their compressors was to replace five old units with two energy-efficient models. This qualified for a RETROFIT PROGRAM incentive which resulted in an impressive payback of mere months. The entire project, from proposal to commissioning, was completed in just six months.

“Compressors are at the heart of the operation here. They run 24/7. Every line has equipment which is driven by compressed air. Before the project, compressors consumed about 20 per cent of overall electricity. Now it’s down to 10 per cent. We’ll see those savings compounded year after year.”

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FOR BUSINESS

KIK Custom Products

PROJECT STATISTICS

By replacing 5 inefficient compressors with 2 energy-efficient units, KIK Custom Products cut annual electrical costs by over $180,000. The incentive reduced the project cost to $83,245, which created a payback of just 6.4 months.

Total project cost: $191,370

Demand savings: 194.4 kW

Energy savings: 1,700,000 kWh/yr

Electricity savings: Over $180,000/yr

Incentive: $95,685

CAsE sTudy

March 2014

RIghT:

Kamen Petrov, Engineering Manager, KIK Custom Products

A 6.4-month payback — that’s big savings out of thin air

What is compressed air costing you?

Ontario manufacturers spend up to 20 per cent of their electricity bills on

typically use 20 to 50 per cent more electricity than necessary. Start

leaks, implementing equipment such as zero loss drains and then

compressors themselves. The payoff is often immediate.

Many operators have never monitored the energy use of their compressed air system, and therefore don’t know the true costs. This table outlines the typical per motor consumption costs based on hours of operation (assumes $0.10/kWh).

The right savings solution isn’t always obvious

Call Toronto Hydro to discuss your system. You may qualify for incentives for an energy audit or engineering study

offer up to 100 per cent funding* to hire an expert to conduct a system audit.

“Take advantage of the incentives.”

Petrov’s advice for other businesses: “Anybody looking at these projects will

prices go up. It would be simply foolish not to take advantage of them.”

“In addition to the direct cost savings from energy consumption, we also benefited from cost avoidance, not having to deal with repair and maintenance for the next 5 to 10 years.”

Kamen Petrov, Engineering Manager, KIK Custom Products

Visit torontohydro.com/businessfor more information or to apply online for incentive programs. Hotline: 416.542.3388 Fax: 416.542.2980 email: [email protected]

*Incentives are subject to maximum amounts based on the potential saving and the applicable incentive program. Subject to additional terms and conditions found at torontohydro.com/business. Subject to change without notice. Programs are funded by the

exclude taxes. OM ®A registered trademark of Toronto Hydro Corporation.Used under licence. ‘Toronto Hydro’ means Toronto Hydro-Electric System Limited.

Toronto Hydro Incentive Programs

Toronto Hydro offers saveONenergy programs that

technical assistance to help

With programs available for commercial, institutional, multi-residential and industrial buildings, conservation can be an attractive investment opportunity with excellent returns. Discover your best energy-saving opportunities by starting with an energy audit and then apply for the appropriate incentive programs for further funding.

Compressor size

1 Shift (2,250 hrs)

2 Shifts (4,250 hrs)

3 Shifts (8,400 hrs)

10 HP $1,720 $3,250 $6,43025 HP $4,300 $8,130 $16,060100 HP $17,120 $32,330 $63,900

Based on $0.10/kWh

Plastics manufacturer maintains operations while reducing energy usage and costs

The Big Picture

ORBIS Corporation is a part of Menasha Corporation, an innovative manufacturing company with over 160 years of history. ORBIS provides reusable plastic containers and other packaging systems to customers all over the world. With 10 locations in the US and Canada, their manufacturing plant in Toronto uses multiple presses, a grinder and an extruder to produce thousands of plastic products a year.

ORBIS Corporation strives to make a positive difference in communities in which it operates and it is committed to improving the environment. In 2010, ORBIS launched its first Annual Sustainability Report to ensure they provide solutions that both create economic value and are as friendly to the environment as possible.

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DEMAND RESPONSE

ORBIS Corporation

Industry: Plastics Manufacturing

Location: Toronto, Ontario

DR Program: saveonenergy DEMAND RESPONSE DR3 (DR3)

DR Strategy: Curtailment

Primary Curtailment Strategy: Temporary shutdown of grinder and extruder

Annual Payments: Approximately $10,700 per year

CASE STUDY

January 2014

RIGHT:

ORBIS Corporation, Toronto Facility

ORBIS Corporation breaks the mold with DR3 in Toronto

Reducing Costs

In April 2010, ORBIS worked with Toronto Hydro and EnerNOC to participate in the saveonenergy DEMAND RESPONSE DR3 program. ORBIS was determined to reduce its energy demand and cut costs.

While the financial and environmental benefits were enticing, ORBIS conducted a close evaluation of the impact of demand response on its business. At first, ORBIS leaders did not like the idea of shutting down any manufacturing equipment. “Our operations run 24 hours, 7 days a week, every day of the year. We can’t stop production, even if it is for a couple of hours,” said David Berg, Maintenance Manager at the Toronto facility. However, when they learned that Toronto Hydro and EnerNOC would work with them to design a customized plan that would minimize disruption to the business, they became comfortable with a curtailment strategy that works well with their operations. During a dispatch, ORBIS shuts down some of the machines that are not process-critical, like the grinder and the extruder. They also pay close

attention to the weather and decide if they can adjust any other non essential load, like air conditioning or lighting. Depending on the orders they have that day, they can even shut down some of the molding machines.

Planning Ahead

Since joining the program in 2010, ORBIS has been dispatched an average of six times per year. Dispatches in Toronto tend to occur during the summer months, when peak demand is high. “Planning for a dispatch is easy. EnerNOC notifies me in advance, and I inform plant workers. We adjust our operations accordingly, and everyone knows we are participating in demand response,” said Berg.

As part of its participation in DR3, ORBIS received EnerNOC’s powerful online energy profiling software that gives Berg access to real time energy data. Using this tool, he can decide which machines to shut down in order to reduce demand to the desired load.

The Future

Participating in demand response is helping ORBIS achieve its sustainability goals, and helps Toronto Hydro fulfill its commitment to energy conservation. As part of Menasha Corporation, leaders at ORBIS are clearly focused on respecting and protecting the environment for today and for generations to come. “Sustainability is a big part of what we do,” added Berg. The energy curtailment plan is an integral part of ORBIS’s strategy to reach a 20% absolute reduction in carbon emissions target by 2020.

“We were looking for ways to reduce our electricity cost. With demand response, we offset our peak, and we get paid to do it. It’s that simple.”

David Berg, Maintenance Manager

torontohydro.com/demandresponseHotline: 416.542.3388 Fax: 416.542.2980 email: [email protected]

Subject to additional terms and conditions found at torontohydro.com/demandresponse. Subject to change without notice. Funded by the Ontario Power Authority and offered by Toronto Hydro. A mark of the Province of Ontario protected under Canadian trade-mark law. Used under sublicence. OMOfficial Mark of the Ontario Power Authority. Used under licence. ®A registered trademark of Toronto Hydro Corporation used under licence. “Toronto Hydro” means Toronto Hydro-Electric System Limited.

Shed Load. Get Paid.

Earn payments for reducing electricity use on demand. There are many ways to participate in DR3, including:

• Powering down non-critical equipment and lighting

• Shifting production to an off-peak period

• Generating your own power

Economy & Finance

Business and Industrial Case Studies