Cynergy meat processing sector v2.pptx
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Transcript of Cynergy meat processing sector v2.pptx
![Page 1: Cynergy meat processing sector v2.pptx](https://reader031.fdocuments.us/reader031/viewer/2022030305/58708eb81a28ab412b8b50c1/html5/thumbnails/1.jpg)
COLD INTELLIGENCE
Meat Processing Sector Meat Processing Sector
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INDUSTRIAL REFRIGERATION FACTS
Accounts for 30 – 70 % of Electricity Spend
Upto 50% More Than Is Required
The GOOD NEWS ?
Refrigeration Plants Can Be Optimised For Significant Savings With Little CAPEX
Meat Processing Sector Refrigeration Facts
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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 ?
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INDUSTRIAL REFRIGERATION FACTS
Typical Meat Plant Refrigeration Requirements
• Carcass Chill – Chill carcass from 38 deg C to 7 deg C in 24hrs or less– Temp range -10 deg c to + 2 Deg C typically
• Maturing Chills – For maturing carcasses in – tenderise the meat
• Boning Hall– Legal requirement to keep at 7 deg C
• Blast Freezer – Cool product to -18 deg C in 24hrs
• Cold stores – Hold product at -22 deg C until transported off site
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INDUSTRIAL REFRIGERATION FACTS
Meat Chilling Operational Factors
• Operate chillers to meet many mutually exclusive requirements,
namely:
– Minimise energy consumption
– Microbiological control
– Optimum surface fat condition and thus downstream productivity
– Cold shortening and appearance
– Weight loss
– Productivity
– Humidity Control
• Normally this is carried out with limited information and control
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INDUSTRIAL REFRIGERATION FACTS
Common Issues in Meat Chilling
• Sub-Optimum Loading– Part loaded– Least efficient chiller first
• Peak load occuring @ peak electrical cost
• Doors open longer than required
• Wash down just before / during loading
• Poor defrost management
• Poor fan control
• Condensation
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INDUSTRIAL REFRIGERATION FACTS
Efficient 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
• Intelligent dynamic control of distribution infrastructure– Pump VSDs (if secondary refrigerant used)
– Evaporator Fan VSDs – Electronic Expansion Valve control
• To Minimise Drip/Weight Loss– Minimise Temperature Differential (TD) between refrigerant and air– Minimise room air velocity
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INDUSTRIAL REFRIGERATION FACTS
CONTROL is Key
Cynergy Dynamically Optimises The ‘Whole’ Industrial Refrigeration System
Production Needs
Ambient Conditions
Compressors
Condensers
Evaporators
EEVs & Pumps
Introducing ..
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INDUSTRIAL REFRIGERATION FACTS
Introducing ..
Cynergy Pre- & Post-Implementation
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INDUSTRIAL REFRIGERATION FACTS
Introducing ..
Cynergy Pre- & Post-Implementation
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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
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WIDESPREAD REFRIGERATION PERFOMANCE & EFFICIENCY ISSUES ACROSS SECTOR
90%
70%
60%
% of Our Client Base Had …
Energy Savings Delivered
15 – 40%
15 – 30%
10 – 30%
Inefficient Distribution System
Inefficient Compressor Start / Sequencing / Type
Additional Typical Inefficiencies Incorrect Condenser Piping – No Liquid Traps
No Utilisation of Free HeatDecentralisation of Plant / Inefficient PACKs
Manual Energy Consumption MonitoringRefrigerant Choice / Secondary Refrigerant Concentration
Inefficient or No Real-Time Control vs Production Needs & Ambient Conditions
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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
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INDUSTRIAL REFRIGERATION FACTS
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INDUSTRIAL REFRIGERATION FACTS
SECURE CLOUD-BASED REAL-TIME OPTIMISATION ENGINE & REPORTING PLATFORM
PRODUCTION FACILITY CLOUD / INTERNET
• CUSTOM DASHBOARD• ‘SPARK’ ALERTS• SAVINGS PERFORMANCE
MASTER
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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
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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
Engine200 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
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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
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INDUSTRIAL REFRIGERATION FACTS
DRAMATIC & IMMEDIATE CONTROL & EFFICIENCY IMPACT
£££
Major Project Undertaken
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INDUSTRIAL REFRIGERATION FACTS
CUSTOMISED CONSUMPTION vs PRODUCTION DASHBOARDS
£££
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INDUSTRIAL REFRIGERATION FACTS
TRACK ENERGY CONSUMPTION vs Kg PRODUCT RATIO
£££
21
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INDUSTRIAL REFRIGERATION FACTS
TRACK REAL-TIME SAVINGS
£££
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INDUSTRIAL REFRIGERATION FACTS
HOW ARE SAVINGS CALCULATED ?
£££ We have extensive experience optimising refrigeration systems in Meat Processing Plants
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
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INDUSTRIAL REFRIGERATION FACTS
ADDITIONAL SAVINGS - RED ZONE PEAK CHARGE AVOIDANCE
£££
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INDUSTRIAL REFRIGERATION FACTS
CYCLE OFF COLD STORES – CYNERGY CONTROLLED• Typically Cold Stores are on all the time
– Doors open for much of the day
• We would propose trialing turning the fans and compressors off for period(s) of the day – Up to 6hrs/day eventually – Drop suction temp to -38 deg C in advance of turn off
• This would be undertaken via a trial with customer – Trial how long it takes for temp to drift up
• One possible way of achieving this is running the cold stores to -26 deg C prior to electricity red band period – Let temperature float back to set point over the 2 hr red band period
• Contingency function:– If cold store temp goes 1 deg above set point turn the plant back on
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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 !
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INDUSTRIAL REFRIGERATION FACTS
OUR STRAIGHTFORWARD OFFERING
£
OLD ENERGY
COST NEW ENERGY
COST
SAVING
FEE
GUARANTEED SAVINGS
PLUS CONTROL INFRASTRUCTURE
PLUS REAL-TIME VISIBILITY
PLUS REAL-TIME ALERTS
NO COST TO CUSTOMER
MONTHLY FEE FROM SAVING
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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/mthBASED ON £250K ANNUAL REFRIGERATION SPEND
20% REDUCTION IN ENERGY = £4,167/mth
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TRUSTED CLIENTS OF
Bernard Matthews
Cranswick Group
Linden Foods
Tennents Lager
Johnson & Johnson
GE Healthcare
Direct Table Foods
Aliaxis Group
Emrill
COLD INTELLIGENCE
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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
+353 1 274 8880
COLD INTELLIGENCECOLD INTELLIGENCECOLD INTELLIGENCE