INDUSTRIAL BAKERY:FROM NATURAL GAS CONSUMPTION ANALYSIS TO $AVINGS

GreenQ Partners demonstrates how statistical analysis of consumption data uncovers gas saving opportunities and more

WHO WE ARE

GreenQ Partners is a Toronto-based consulting firm that helps clients save energy while becoming greener.

www.greenq.ca

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Anatoli Naoumov, a Managing Director of GreenQ Partners, has been helping clients cut costs and increase profits for over 15 years.

Anatoli is certified as measurement and verification professional (CMVP) by the Association of Energy Engineers (AEE) and the Efficiency Valuation Organization (EVO).

WHAT ANALYSIS?

We analyse gas consumption data in relation to its key drivers (such as production level and weather) to quantify the relationship and to find out how this relationship changes over time.

Any change in consumption-production-weather relationship equals to a change in efficiency and signals either a saving opportunity or an operational issue.

We do not sell any equipment, but we can confirm factual or calculate expected savings from energy efficiency measures in client’s particular conditions.

All analysis is done in accordance with recommendations of International Performance Measurement and Verification Protocol (IPMVP) established Efficiency Valuation Organisation (EVO).

We use RETScreenPlus software developed by NRCan.

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HOW CAN AN INDUSTRIAL BAKERY BENEFIT?

With results of our analysis bakery manager may answer such practical operational questions as:

Has per kg gas consumption changed since last maintenance? How does it vary month to month, season to season?

Should we reheat oven or keep it running during non-production time?

What is the marginal cost to bake another 1,000 kg of buns?

Do we save gas from that gizmo installed 3 months ago?

….. and many more

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PROCURE GAS IN ADVANCE AND SAVE

One of the results of our analysis is formula that allows to forecast the need for natural gas based on energy use pattern and production plan.

Example of natural gas need forecast formula:

Daily consumption, m³ =

C1* Production Forecast, kg

+ C2*Average temperature

± deviation, with 95% confidence

Where C1 and C2 are calculated for operational conditions of particular bakery.

With such forecast CFO of an industrial bakery can minimize dependence on volatility of natural gas spot prices by procuring gas in advance.

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How much would your industrial bakery save with such forecast tool?

EFFICIENCY IS MORE THAN COST OF GAS

Efficiency change signals operational or technical issues:

Some burners malfunction Uneven temperature causes over/under baking

Longer production cycle

Air intake filter is dirty Incomplete combustion causes sod accumulation

Air intake fan is overloaded, higher electricity consumption

Oven is overused Deviation from operation schedules

Incomplete load

Unaccounted oven use

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WHAT DID WE FIND LAST TIME?

In a recent project conducted at a commercial bakery we have found: Inadequate maintenance procedure resulted in consumption worth $5,000 in 2011

and $11,000 in 2012.

Baking an additional 1 kg of rolls required 0.38 m³ of gas in winter compared to 0.028 m³ in summer.

Winter non-production consumption increased year-to-year by 2,000 m³ and 5,000m³.

Confirmed weather-adjusted gas saving from technological improvement in amount of $3,000 in 2011 and $7,000 m³ in 2012

Statistically reliable formula connecting gas consumption and production; to be used for costing and budgeting instead of “average per kg gas consumption”

Utilization of rejected heat for preheating combustion air alone can save up to $100,000. Other uses of low grade heat are possible.

Unexplained temporary decrease of about 90,000 m³ in non-oven gas use.

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How much would this be worth for your business?

WHAT IS NEEDED FOR ANALYSIS?

Production data: daily or per period if production level is consistent

Gas consumption data: ideally - per oven, daily or per period if production level is consistent

General description of how measured equipment is used: shifts, daily load, operation schedule, service intervals, changes within periods for which data is provided.

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What is one accurate analysis worth then?

FAQ

Can this analysis be used for other utilities? For other technologies? Yes, in the same way we can analyse electricity use for baking or refrigeration.

Actually, in any other repetitive industrial process too.

We do not have weather data, how will you perform analysis? We can obtain actual weather data for any location from NASA

Our production periods differ from utility billing cycles We can account for any periods, as long as start and end dates are known

We do not submeter each oven, only have one utility meter Some analysis still can be performed, but accuracy will be lower. If ovens are of

the same type and load is spread evenly accuracy will approach that of sub-metered ovens.

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