How leading meat processing companies are driving down refrigeration/cooling electricity costs

1. COLD INTELLIGENCE
Meat Processing Sector Meat Processing Sector

2. 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

3. 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 ?

4. 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

5. 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

6. 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

7. 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

8. INDUSTRIAL REFRIGERATION FACTS
CONTROL is Key
Cynergy Dynamically Optimises The ‘Whole’ Industrial Refrigeration System
Production
Needs
Ambient
Conditions
Compresso
rs
Condensers
Evaporators
EEVs &
Pumps
Introducing ..

9. INDUSTRIAL REFRIGERATION FACTS
Introducing ..
Cynergy Pre- & Post-Implementation

10. INDUSTRIAL REFRIGERATION FACTS
Introducing ..
Cynergy Pre- & Post-Implementation

11. 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

12. 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 Heat
Decentralisation of Plant / Inefficient PACKs
Manual Energy Consumption Monitoring
Refrigerant Choice / Secondary Refrigerant Concentration
Inefficient or No Real-Time Control vs
Production Needs & Ambient Conditions

13. 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

14. INDUSTRIAL REFRIGERATION FACTS

15. INDUSTRIAL REFRIGERATION FACTS
SECURE CLOUD-BASED REAL-TIME OPTIMISATION ENGINE & REPORTING PLATFORM
PRODUCTION FACILITY CLOUD / INTERNET
• CUSTOM DASHBOARD
• ‘SPARK’ ALERTS
• SAVINGS PERFORMANCE
MASTER

16. 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

17. 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

18. 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

19. INDUSTRIAL REFRIGERATION FACTS
DRAMATIC & IMMEDIATE CONTROL & EFFICIENCY IMPACT
£££
Major Project
Undertaken

20. INDUSTRIAL REFRIGERATION FACTS
CUSTOMISED CONSUMPTION vs PRODUCTION DASHBOARDS
£££

21. INDUSTRIAL REFRIGERATION FACTS
TRACK ENERGY CONSUMPTION vs Kg PRODUCT RATIO
£££
2
1

22. INDUSTRIAL REFRIGERATION FACTS
TRACK REAL-TIME SAVINGS
£££

23. 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

24. INDUSTRIAL REFRIGERATION FACTS
ADDITIONAL SAVINGS - RED ZONE PEAK CHARGE AVOIDANCE
£££

25. 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

26. 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 !

27. 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

28. 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
t
At Your Expense
t
TYPICAL FEE : £2,000/mth
BASED ON £250K ANNUAL REFRIGERATION SPEND
20% REDUCTION IN ENERGY = £4,167/mth

29. TRUSTED CLIENTS
OF
Bernard Matthews
Cranswick Group
Linden Foods
Tennents Lager
Johnson & Johnson
GE Healthcare
Direct Table Foods
Aliaxis Group
Emrill
COLD INTELLIGENCE

30. NEXT STEPS
If 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
COLD INTELLIGENCE
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