A top-tier US poultry processing company sought a partnership to achieve real-time insights into energy consumption and production processes. The objective was to track product movement, power, water, and natural gas usage in every five minutes as well as implement alerts and alarm systems for overuse and downtime tracking. Here is a step-by-step guide detailing the execution of this project.

Step 1: Installation of a Real-Time Monitoring Platform

The first step undertaken was the integration of a proprietary real-time monitoring platform within the plant. This platform was designed to track power, gas, and water usage as well as production statistics every five minutes.

Step 2: Identification of Process Variations

The monitoring platform showcased significant variations in ‘live count’, leading the team to conduct extensive audits. These audits confirmed the accuracy of the newly implemented counting system. Accurate metrics now enabled real-time labor efficiency and tracking of ‘missed shackles’.

Step 3: Enhanced Visibility Through Panel Installations

To provide detailed visibility to the management, more monitoring panels were installed. This allowed real-time tracking of bird location and labor efficiency per processing line and department.

Step 4: Water Meters and Identification of Hidden Issues

Water meters were also put into place to track the usage of water per product, which unveiled previously undisclosed issues like disparities in water use between different work shifts. Using real-time data, various operational inefficiencies, such as improper repair work leading to significant water wastage, were quickly identified and rectified.

Step 5: Resolution of Power Quality Issues

The monitoring solution helped fix power quality issues. Real-time monitoring highlighted voltage fluctuations and helped trace the cause of variable frequency drive (VFD) and soft starter failures. With assistance, the company initiated a conversation with their utility provider to resolve these issues, which were attributed to capacitor banks not removed during a plant relocation.

Step 6: Provision of Real-Time ESG Metrics

Finally, their real-time monitoring system started providing ESG (environmental, social, and governance) metrics in response to management’s need to track carbon intensity per product and provide scope 3 emissions data to clients. These capabilities offered a competitive advantage by meeting demands for sustainability metrics.

Outcome

In summary, implementing this real-time monitoring solution enabled the poultry processing company to significantly enhance operational efficiency, reduce waste, and boost their ESG performance.

A property management company sought to upgrade and enhance energy efficiency in a large metropolitan skyscraper. The building, constructed in the 60s, was experiencing substantial energy inefficiencies and had difficulties accurately billing tenants for electricity use. Here is a step-by-step guide on how the company achieved their objectives.

Step 1: Energy Consumption Assessment and Identification of Improvement Areas

The first step involved deploying a team of energy experts to assess the building’s energy usage and pinpoint areas requiring enhancement. This involved a comprehensive review of the building’s current state of energy consumption.

Step 2: Lighting Retrofit

Next, the team completed a lighting overhaul. Fluorescent tube lights were replaced with energy-efficient LED and GHID lights, reducing lighting demand and cost by approximately 50%. This improvement not only led to a reduction in energy consumption but also improved lighting quality and safety. Financial support for this upgrade partly came from available utility rebates.

Step 3: Equipment Upgrade

Post the lighting retrofit, the team identified malfunctioning variable frequency drives (VFDs) for replacement. The incorporation of new VFDs enabled the building to swiftly decrease electric demand by over 500 kW in 15 seconds during peak demand periods or strained grid conditions. Intelligent controls were integrated to facilitate this immediate demand reduction, tapping into added demand response revenue and responding to grid price signals.

Step 4: Implementation of a Network Backbone

As an aspect of the implementation, a modern network infrastructure was put in place. This infrastructure allowed real-time tracking and regulation of assorted building data, such as voltage, amperage, and harmonics.

Step 5: Installation of Enhanced Smart Meters

Moreover, advanced smart meters were installed floor-wise to monitor tenant power demand and usage.

Step 6: Uploading Data to an Online Platform

All the data collected was auto-uploaded to a dedicated online platform. This tool allowed tenants to track and cut-down their power consumption and streamlined the process of generating and distributing invoices.

Step 7: Optimal Procurement Strategy

An effective procurement strategy was crucial in decreasing the building’s power obligation, resulting in a lower supply rate. This strategy ensured that the client did not over-hedge or under-hedge based on variable building occupancy and fluctuating energy consumption.

Outcome

This structured process led to substantial cost savings, a decrease in carbon emissions, and improved curtailment capabilities. Beyond immediate benefits, the expert team is also working on future projects with the client, including the incorporation of battery storage, solar PV, cooling towers, and cogeneration units.