Optimizing Resources For Improved Performance CIPEC Energy Summit - - PowerPoint PPT Presentation

Optimizing Resources For Improved Performance

CIPEC Energy Summit 2018

GAY LEA FOODS CO-OPERATIVE LTD MAY 30, 2018

ZBIGNIEW EWERTOWSKI, P.ENG.

DIRECTOR, OPERATIONS TECHNOLOGY

GAY LEA FOODS CO-OPERATIVE LTD. 5200 Orbitor Drive Mississauga, Ontario

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GAY LEA FOODS briefly:

• 11 manufacturing facilities: 9 in Ontario, 1 in Manitoba, 1 in

Alberta

• 662,000,000 litres of milk processed in F2017 (bovine and goat

combined)

• Employees: 1,012
• Sales in F2017: 788 M

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Gay Lea range of products:

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Fluid milk, Cream, Whipped Cream, Various Cheeses, Cottage Cheese, Sour Cream, Butter, Milk Powder, Yoghurt

SPECIFIC NATURE OF DAIRY INDUSTRY

1. Biologically active substrates – dynamic in nature 2. Perishable foods 3. Shear sensitive 4. Heat treatment to destroy pathogenic microorganisms and extend shelf life:

• Pasteurization and sterilization
• Refrigeration and freezing
• Concentration and Drying
• 5. Sanitary aspects
• 6. CFIA compliance

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SAVING ENERGY AND WATER

SAVING ENERGY AND WATER MAKES SENSE FROM A BUSINESS & ENVIRONMENTAL PERSPECTIVE

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ENVIRONMENT

Environmental issues specifically associated with dairy processing facilities include the following:

• Wastewater
• Solid waste
• Emissions to air
• Energy consumption

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BENCHMARKING PROCESS

• By benchmarking energy and water intensity against a known

reference dairy process we can evaluate the energy and water efficiency of our processes

• The reference dairy process is based on existing and proven

practices and technologies identified from available sources.

• Benchmarking can be used as an energy management strategy

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BENCHMARKING cont’d

• The benchmark score values can be used to indicate relative

performance of our dairy process compared to the most efficient process identified e.g. European BAT (Best Available Technology).

• The outcomes from comparisons may become a basis to

evaluate potential for savings and to consider future improvements

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KPI

We develop KPIs for what we can control at the plant operations

• level. Key metrics include reducing kWh of electricity, m³ of

natural gas and water, and kg of BOD concentrations

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EXAMPLES FROM THE BENCHMARKING PROCESS

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PLANT "A" Electricity Usage (2016)

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0.138 0.137 0.150 0.136 0.161 0.167 0.180 0.163 0.168 0.171 0.148 0.222 0.000 0.050 0.100 0.150 0.200 0.250 kWh adj./Litre Milk Month Electricity (kWh adj./L) Average

Plant "A" Natural Gas Usage (2016)

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0.022 0.025 0.023 0.021 0.021 0.018 0.015 0.017 0.018 0.020 0.021 0.027 0.000 0.005 0.010 0.015 0.020 0.025 0.030 Cubic Meter/Litre Milk Month Gas (m3/L) Average

Plant "A" Water In Usage (2016)

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3.388 3.696 4.026 3.502 3.995 3.732 3.694 3.310 3.650 3.899 3.422 5.187 0.000 1.000 2.000 3.000 4.000 5.000 6.000 Litre Water/Litre Milk Month Water In (L/L) Average

Plant "A" Wastewater Generation (2016)

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3.082 2.750 2.877 2.520 2.890 2.804 2.823 2.555 2.785 3.162 2.810 4.827 0.000 1.000 2.000 3.000 4.000 5.000 6.000 Litre Water/Litre Milk Month Water Out (L/L) Average

GAY LEA FOODS’ RESOURCES SAVING INITIATIVES

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WATER

• Reduction of demand for water in processing
• Reduction of demand for water in cleaning
• Reduction of demand for water in utilities
• Water recycling and reuse
• Wastewater treatment processes

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ENERGY: ELECTRICITY AND HEAT

• Conducted Audits to identify opportunities
• Implementation of the findings in the compressed air and

steam

• Heat recovery

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YIELD OPTIMIZATION AND PRODUCT RECOVERY

• Sources of product loss
• The cost of product loss
• Efficient processing and process control
• Minimizing waste
• Maximizing product recovery

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GOAL

Reduce first, Recover-Reuse last

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Q&A

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