An Illinois protective packaging manufacturer was able to reduce their cooling costs by over 60% while also saving around $100,000 each year on system maintenance by replacing their old system with high-efficiency equipment and a streamlined hydronic design. Helped by ComEd efficiency incentives, the plant captured these benefits through an under 2.4 year payback system upgrade project.
The Sterling Heights facility, producing jet engines for the U.S. Army, has undergone extensive overhauls and re-tooling in the last decade. In 2010, Stellantis announced it would invest nearly $850 million in a new state-of-the-art paint shop at the SHAP Site, as well as the installation of new machinery, tooling and material-handling equipment. The following year, the company added another $165 million to the investment to build a one million-square-foot body shop.
An Illinois food service products manufacturer now saves nearly 60% of their base annual cooling energy costs through improvements made in three phases over several years. The plant, which has a 1200 ton chilled water plant, implemented upgrades including pump and tower fan VFDs and enhanced function controls, free cooling, and chiller compressor drive retrofits. The revisions built through successive phases to capture further benefits from more complete utilization of the preceding steps’ capabilities.
The 2022 International Production & Processing Expo (IPPE), was held January 25-27, 2022 in Atlanta with more than 500,000 square feet of exhibit space and 1,140-plus exhibitors. Attendee numbers had not been released when this was written. Sponsored by the U.S. Poultry & Egg Association, American Feed Industry Association and the North American Meat Institute, IPPE is the world's largest annual poultry, meat and animal food industry event of its kind.
With the approaching HFC phasedown, the demand for environmentally friendly cooling systems is driving chiller manufacturers to innovate. Washington-based Pro-Refrigeration, Inc., a leading manufacturer and supplier of chillers for the industrial and beverage processing market, including the dairy, beer and wine industries, recognized an opportunity with CO2 chillers.
A technology called, “cool storage” offers a reliable, cost-effective means of managing electricity costs while ultimately helping to limit greenhouse gas emissions. The technology allows facilities to take advantage of less costly electricity available at night and functionally save that energy for use at a later time. Cool storage achieves this performance by using ice or chilled water as a medium for storing and deploying energy.
Röchling required a new comprehensive cooling system for their facility. The forward thinking management elected to pursue a system that was not only reliable and cost effective, but would incorporate industry leading technology for efficiency and built-in designs for redundancy. Their facility required both a cooling tower system and a chiller system. Below are the design features of each of these Thermal Care systems, and the benefits of some of the unique features are explained.
Our simplified business model is to melt plastic and cool it back into the form we want – and cooling water makes this happen. We need to optimize chilled water temperature and flow to ensure that our production machines make consistent finished products. In molding application, we cool the plastic through conduction and convection directly. Blown film is different in that cooling-water cools the air and then an air handler cools the plastic.
Hospitals account for nearly 5% of the total energy use in the United States each year. The average 200,000 ft2 facility spends about $13,600 per bed, or roughly $680,000 annually, on energy costs. Why so much? Operating twenty-four hours a day, thousands of employees, patients, and visitors cycle through campus buildings daily. Additionally, hospitals maintain high ventilation rates to lessen the risk of microbial contamination; the conditioning requirements of this outdoor air represents significant energy usage. Lastly, the use of sophisticated imaging equipment, electronic health record systems and other operations generates heat that must be compensated for via the site’s cooling load.
In 2010, an 800-ton water-cooled chiller was installed at the SFP plant to provide process chilled water to support the active diffusion process in the plant. The 800-ton chiller was connected to a common header with a 600-ton and a 1,000-ton chiller in a closed-loop system supporting the production process. The chillers run year-round to create a constant 40°F water temperature for production equipment in the plant.
In February 2021, Chiller & Cooling Best Practices Magazine interviewed members of the Intertape Polymer Group Inc. (IPG) Sustainability Pillars team to gain an understanding of the work being done to improve energy efficiency. The team members interviewed were Michael Jones (Director of Corporate Energy), Michael Deitering (Senior Project Engineer), Jarrod Knapp (Maintenance Manager) and Mark Secord (Engineering Group Leader).