COLD INTELLIGENCE

Brewing Sector

Brewing Sector

INDUSTRIAL REFRIGERATION FACTS

Accounts for 30 – 50 % of Electricity Spend

Upto 50% More Than Is Required

The GOOD NEWS ?

Refrigeration Plants Can Be Optimised For Significant Savings With Little CAPEX

Brewing Sector Refrigeration Facts

INDUSTRIAL REFRIGERATION FACTS

• Plants are typically set up for ambient conditions which occur for less than 2 weeks of the year

• Maintenance contractors are incentivised to get plants up and running quickly, minimise call out frequency and duration – at the expense of energy efficiency

• Site facilities staff are typically not refrigeration experts

• Maintenance contractors rarely take ‘whole system’ view and their energy impact is rarely monitored

• There is typically minimal plant monitoring in place so the effects of sub par maintenance or process changes go unnoticed

• Process loads and conditions typically change over time and the plant is never recommissioned to optimally handle new loads and profiles

Why So Inefficient ?

INDUSTRIAL REFRIGERATION FACTSTypical Brewery Shock Loads

INDUSTRIAL REFRIGERATION FACTS

• Fermentation Typically Beer cooled kept at circa 21 deg CCooled before exit of FV’s to 8-14 deg C

• Wort Cooling Typically wort cooled to 12-14 degrees C

• Beer Chilling before final packing Typically -1 to -2 deg C

• Large central plants installed to meet all cooling loads Lowest common denominator = -4 deg C glycol

• Refrigeration plants are not typically controlled dynamically For example they typically do not ramp up glycol temperature when only Fermentation cooling is occurring

Typical Brewing Sector Cooling Loads

INDUSTRIAL REFRIGERATION FACTSReducing / Removing Shock Load Variability

• Many plants are controlled on a glycol exit setpoint

• Driving compressors to do whatever is required to maintain this set point– Calls for lag compressors when not necessarily required – only to

quickly drop out again

• This leads to excessive energy consumption in the plant

• Optimum compressor efficiency is achieved via dynamic control of both suction & discharge pressures to meet ambient & process need conditions - 1 bar reduction in discharge pressure = 7.5% reduction in electricity consumption

• Use the glycol infrastructure to manage & reduce shock load changes:– Utilise large distribution pipework infrastructure as a buffer – Hot and cold buffer tanks – Cold glycol spill back

INDUSTRIAL REFRIGERATION FACTSChilled Water for Wort Cooling

▪Often refrigeration plant is used to cool incoming towns water from ambient (5-22 deg C) to 6-10 deg C

▪6 deg C CHW is used to cool wort to target temp of 14 deg C before Fermentation

▪Cooling load varies by 300% winter to summer as ambient water temp varies

INDUSTRIAL REFRIGERATION FACTSChilled Water Optimisation

▪Possible to use returning “warm” to cool CHW for wort cooling

▪This will have the effect of:▪Widening glycol delta T – by up to 1 deg C in summer

time ▪Reducing energy consumption on compressors

▪Additional Optimisation Opportunities:▪use incoming borehole water to drop temp of towns water

in summer – this will in turn heat borehole water by circa 7 deg C i.e. circa £32k in gas savings ▪Use “warm” glycol to vapourise CO2 or N2

INDUSTRIAL REFRIGERATION FACTSEfficient Refrigeration Control Best Practices

• Dynamically control and vary suction and discharge setpoints based on ambient and process conditions versus fixed setpoints

• Ensure compressors are controlled for optimal loading:– Screw Compressors are loaded in excess of 70% on

average – Reciprocating Compressors acting as Trim compressors

• Ensure stable & efficient operation of distribution pumps – Optimised via intelligent pump VSD control

• Track energy consumption vs production and ambient conditions

• Track impact of operations & maintenance

INDUSTRIAL REFRIGERATION FACTS

CONTROL is Key

Cynergy Dynamically Optimises The ‘Whole’ Industrial Refrigeration System

Production Needs

Ambient Conditions

Compressors

Condensers

Evaporators

EEVs & Pumps

Introducing ..

INDUSTRIAL REFRIGERATION FACTS

Next-Generation Industrial Refrigeration Control

Solution

Real-Time Adjustment & Balancing of Refrigeration

Plant

Production Needs OPTIMALLY MET – ALWAYS

Removes 20 – 50% Energy Costs

No Cost To Client – Fully Paid Via Guaranteed

Savings

Immediate Positive Cashflow & Control To You at No

Risk

WIDESPREAD REFRIGERATION PERFOMANCE & EFFICIENCY ISSUES ACROSS SECTOR

90%

70%

60%

% of Our Client Base

Had …

Energy Savings

Delivered15 – 40%15 – 30%10 – 30%

Inefficient Distribution System

Inefficient Compressor Start / Sequencing / Type

Additional Typical Inefficiencies Incorrect Condenser Piping – No Liquid

TrapsNo Utilisation of Free Heat

Decentralisation of Plant / Inefficient PACKsManual Energy Consumption Monitoring

Refrigerant Choice / Secondary Refrigerant Concentration

Inefficient or No Real-Time Control vs Production Needs &

Ambient Conditions

INEFFICIENCY DRIVEN BY LACK OF CONTROL & NO PRODUCTION CONTEXT

Impact

• Fixed / Semi-Fixed Discharge & Suction Pressures

• No Ambient Condition Linkage• No Process Load Prediction Control • No VSDs on Condenser & Evaporators• No EEVs• No Defrost Optimisation

Inefficient Distribution System

Inefficient Compressor Start / Sequencing / Type

Inefficient or No Real-Time Control vs Production Needs &

Ambient Conditions

Root Cause

• No Flow vs Process Load Control• No VSDs on Pumps

• Inefficient Load Sharing • No Part Load Optimisation• No VSDs• No Smart Starting and Trimming• No Compressor vs Secondary Pump

Control

INDUSTRIAL REFRIGERATION FACTS

INDUSTRIAL REFRIGERATION FACTS

SECURE CLOUD-BASED REAL-TIME OPTIMISATION ENGINE & REPORTING PLATFORM

PRODUCTION FACILITY

CLOUD / INTERNET

• CUSTOM DASHBOARD

• ‘SPARK’ ALERTS• SAVINGS

PERFORMANCE

MASTER

INDUSTRIAL REFRIGERATION FACTS

EFFICIENCY + PERFORMANCE = WINNNG STRATEGY

SECURE CLOUD-BASED REAL-TIME OPTIMISATION ENGINE & REPORTING PLATFORM

Inspired By Real-Time Formula 1

Data-Driven Decision Making

Technology

~300 Sensor Inputs

Car Sensor Data (Telemetry)

Sent For Remote

Analysis & Processing

Energy Conservation &

Performance Optimisation Instructions

Returned to Car

INDUSTRIAL REFRIGERATION FACTS

CLOUD-BASED Cynergy FAR EXCEEDS TRADITIONAL LOCAL PLC FUNCTIONALITY ..

Plant Data Collected:

Ambient Conditions,

Production Needs & Refrigeration

Plant Status

Telemetry Sent For Remote

Processing by Cloud-based

Cynergy Logic Engine

200 Control Rules C.O.P.

£££

C.O.S.P.

Optimised Refrigeration

System Setpoints Sent Back to Plant, Monitored & Monetised

..i.e PREDICTIVE PRODUCTION REFRIGERATION OPTIMISATION, TARIFF REDUCTION

INDUSTRIAL REFRIGERATION FACTS

DIGITISE INSTALL M/C INTERFACES,VSDs, EEVs, AMBIENT CONDITION MONITOR etc BASED ON COST BENEFIT ANALYSIS

OPTIMISE

MONETISE

CUSTOMISE LOGIC ENGINE TOWARDS PLANT OPTIMISATION

ESTABLISH SAVINGS BASELINE MODEL

CUSTOMISE DASHBOARD & REPORTING

3 MONTH ROLL-OUT JOURNEY(TYPICAL OVERALL IMPLEMENTATION TIMESCALE WITH LIMITED ONSITE WORK)

£££

£££s FLOW

INDUSTRIAL REFRIGERATION FACTS

DRAMATIC & IMMEDIATE CONTROL & EFFICIENCY IMPACT£££

Major Project Undertaken

INDUSTRIAL REFRIGERATION FACTS

CUSTOMISED CONSUMPTION vs PRODUCTION DASHBOARDS£££ Major Project

Undertaken

INDUSTRIAL REFRIGERATION FACTS

TRACK ENERGY CONSUMPTION vs PRODUCTION RATIO£££

INDUSTRIAL REFRIGERATION FACTS

Existing Plant

Existing M/C

Control

Existing Plant

Existing M/C

Control

!

COMMS FAULT ? CONTROL AUTOMATICALLY UNCOUPLED & DEFAULT MAINTAINED

Cynergy ONLY ADVISES – DRIVER (Existing Plant Control) STILL IN COCKPIT !

INDUSTRIAL REFRIGERATION FACTS

TRACK REAL-TIME SAVINGS£££

INDUSTRIAL REFRIGERATION FACTS

HOW ARE SAVINGS CALCULATED ?£££ We have extensive experience optimising refrigeration

systems across the Brewing Sector, amongst others

We have developed sophisticated models which predict energy consumption using up to 3 influencing factors

We then check the predictive model against historical usage data to establish a correlation or confidence factor - must be > 80%

Tracking Three Influencing

Factors

INDUSTRIAL REFRIGERATION FACTS

TRACK REAL-TIME SAVINGS & COSTED ALERTS (SPARKS)£££

INDUSTRIAL REFRIGERATION FACTS

ADDITIONAL SAVINGS - RED ZONE PEAK CHARGE AVOIDANCE£££

INDUSTRIAL REFRIGERATION FACTS

OUR STRAIGHTFORWARD OFFERING

£OLD ENERGY COST NE

W ENERGY COST

SAVING

FEE

GAURANTEED SAVINGS

PLUS CONTROL

INFRASTRUCTURE

PLUS REAL-TIME VISIBILITY

PLUS REAL-TIME ALERTS

NO COST TO CUSTOMER

MONTHLY FEE FROM SAVING

THIS IS NOT BUSINESS AS USUAL – WE ASSUME ALL RISK

IMMEDIATE POSITIVE CASHFLOW£

-£

Vendor Profits

TRADITIONAL PURCHASE MODEL

£

-£

You Get Immediate Cash Savings

We Assume All Risk

tAt Your Expense

t

TYPICAL FEE : £2,000/mth

BASED ON £250K ANNUAL REFRIGERATION SPEND20% REDUCTION IN ENERGY = £4,167/mth

TRUSTED CLIENTS OF

Bernard MatthewsCranswick Group

Linden FoodsTennents Lager

Johnson & JohnsonGE Healthcare

Direct Table FoodsAliaxis Group

Emrill

COLD INTELLIGENCE

NEXT STEPSIf you would like to

understand the savings potential of Cynergy

applied to your refrigeration plant,

please contact Crowley Carbon to book a free

initial Opportunity Assessment

www.crowleycarbon.com

cynergy@crowleycarbon.com

+353 1 274 8880

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