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Food Processing Awards - Energy Management

15 August 2013

To cast your vote for the Energy Management category of the Food Processing Awards 2013 simply email your choice to

Energy Management

1) Industrial Washing Machine

T200 traywasher at Smithfield Murray
A customised tray washer is delivering savings of more than £10,000 per year for Smithfield Murray, one of the UK’s most successful suppliers of poultry products.
Smithfield Murray makes extensive use of plastic trays to transport diced and sliced poultry between the processes in its plant and, until recently these trays were washed using a pressure washer. However, it was clear that tray washing was fast becoming a production bottleneck. 
Martin Grady, general manager at Smithfield Murray said: “The benefits we’re getting from the new T200 machine are impressive. It has reduced our water usage by 5 m3 per day, which translates into a cost saving of £12.30 a day for 260 days each year, and we can now do all of our tray washing in half a shift, so it has freed up 4.5 employee hours a day for us to use in other areas. Overall, the savings add up to more than £10,000 per year.”

2) Igus 
Blue detectable energy chain
igus UK, has introduced a blue energy chain that is easy to detect and blue anti-microbial cables. Even in the most modern production lines, machine failure and damage cannot be eliminated, and being able to detect foreign materials quickly in food is vital to guarantee the reliability of food production lines.  

igus’ experts have designed a detectable polymer energy chain by using a special plastic material, igumid DT. As a result, spherical particles of the blue material as small as 1 mm can be detected in fragments passing at speeds of 20m/min by all standard metal detection systems. The blue detectable material igumid DT is available for the reliable E2/000 and E4.1 series energy chains.

The new material has successfully passed the international tests for anti-microbial activity and effectiveness in line with ISO 22196 and JIS Z 2801.

3) Babcock Wanson
ESM Steam Generators - the first Steam Generators to be used with HJ Heinz - have been installed into the company’s Dundalk facility in Ireland as part of a strategy to reduce energy consumption. 
Producing frozen ready meals primarily for the UK, Heinz’s Dundalk plant is a large steam user, using steam in the cooking process and to heat water for wash down. The plant had been using a large old firetube boiler but, as part of an ongoing plan to improve energy efficiency across all operations including the steam boiler system, the decision was made to switch to two Babcock Wanson ESM7000 sequence controlled Steam Generators complete with high efficiency Economisers. These have been installed into a new custom built boiler house.
A coil type Steam Generator, the ESM provides operating efficiencies of circa 96-97% overall and low emissions. It utilises modern controls to maintain a close ratio between the burner firing rate and water input with inverter drive of both the combustion air and feed water pumps. This ensures close control of both steam output and steam quality and lowest practicable consumption of electrical power. 
Heinz’s Dundalk plant has already recently achieved certification under the Energy Agreements Programme (EAP) to IS393:2005 and is expecting further efficiency improvements with the ESM Steam Generators in place. In addition, the ESM7000s will also better match the steam load than the previous system was able to accommodate.
Further benefits of ESM Steam Generators include improved safety, simplicity of control, a compact size and quieter, cleaner and cooler operation. 

4) Daikin City
An online tool introduced by Daikin UK called Daikin City interactive virtual city enables the comparison of energy savings that might be achieved through the use of differing VRV-based technologies food environments with cold store requirements. Visitors can view, via their computer or an iPad app, the impact that different energy efficient options have on an energy calculator, which displays the potential energy savings that could be achieved as part of an overall solution.

This online tool clearly demonstrates the benefits a whole building approach can have in reducing overall energy costs and carbon emissions, helping to improve the all-important bottom line and helping to meet carbon reduction standards and legislation. 
So by taking the whole building’s requirements into consideration as well as the cold store needs, it is possible to create a “virtuous circle” of heat recovery, to greatly reduce energy consumption and cut carbon emissions.

5) Schneider Electric
'Quick pulse' survey is the latest tool introduced by Schneider Electric in a bid to help customers improve their energy management and efficiency.
The specialist in energy management, has announced the launch of its new Efficiency Quotient, described as a quick and easy online questionnaire that provides customers with an energy management assessment, including cross-user comparisons and recommended steps for reducing energy costs and improving efficiency.

The Efficiency Quotient is said to allow customers to make a basic assessment of what they can do to further enhance the efficiency of their assets. Upon completing the survey, customers receive a 'score' on a rating of 1 to 5 compared to other like-users, including building managers, data centers, industrial plants and energy managers. Based on this score, Schneider Electric provides customers with recommendations and access to related white papers, specific links and tools to help guide the energy efficiency improvement process. In addition, CEOs can determine their Enterprise Efficiency Quotient by encouraging their managers across the entire organization to take the survey.

6) Testo
Testo manufacture an extensive range of quality thermal imager cameras, suitable for a wide range of non-intrusive applications all of which guarantee rapid and accurate results with major notable impact on time, cost and safety. Testo thermal imagers are universal and flexible giving an instant status check on any equipment or locate and identify faults. They combine high and super resolution - integrated camera –auto focus – temperature range of -20ºC to + 350º C – fold out display and rotatable handle and voice recording  
Typical sectors are; electrical inspection:  manufacturing process and maintenance :Building inspections:HVAC :Research and Development. 

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