Heads Up CIPEC – Volume 21 No 7 and 8

Table of Contents

The ENERGY STAR Challenge for Industry is on

The ENERGY STAR Challenge for Industry has been launched. The Honourable Jim Carr, Minister of Natural Resources, issued the challenge at the start of the Generation Energy Forum held in Winnipeg, Manitoba in mid-October, 2017. With this announcement, the Minister challenged industrial manufacturing facilities to become more competitive while reducing energy use and greenhouse gas emissions.

“The ENERGY STAR Challenge for Industry is one more way to help us get to that cleaner, more sustainable future. It's also a great way to kick off Generation Energy, which is the culmination of a national conversation we've been having with Canadians to imagine our energy future and a Canada that leads the global transition to a low-carbon economy,” says Carr.

To participate in the Challenge, organizations will implement low- or no-cost actions such as turning off lights and equipment when not in use and fixing leaks in compressed air systems. Companies can achieve even more significant savings with lighting and equipment retrofits.

Additional benefits of participation include increasing a company’s energy management visibility and engaging all business divisions. Moreover, by participating in the Challenge, organizations will build an energy management culture and demonstrate leadership in their industry.

CIPEC leaders who use at least 50 percent of their energy in manufacturing or research and development are eligible to enter the Challenge. Companies must also establish and maintain a file with all relevant energy data from their facility and they must provide proof of a 10 percent reduction in energy intensity over a five-year period.

For more information about the ENERGY STAR Challenge for Industry, click here.

Glenergy Canada aims for net zero

“Our company is about sustainability – it is our raison d’être,” says Glen MacGillivray, President of Glenergy Canada, a manufacturer and distributor of renewable energy products including solar lighting solutions, solar cookers, cell phone chargers, solar showers and appliances. The company provides its solar solutions to off-grid markets in Canada and its low-cost solar system in African communities.

Glenergy, located in Petawawa, Ontario, is situated on just over half a hectare of land and operates in a 465 square metre building. The company has eight employees who work on a regular, five-day-a-week schedule.

Glenergy recently joined CIPEC as a Leader in the general manufacturing sector. MacGillivray says that he felt that it was important to be a part of CIPEC since his company is built on the same sustainability principles. McGillivray is taking those principles to the next level, as his ultimate goal for the company is to be net zero.

On its way to net zero, the company has already implemented a number of energy conservation measures. For example, electric vehicles have been in use for several years and LED lighting retrofits for the whole facility are almost complete. Moreover, the company has moved from physical servers to a cloud-based system, so work stations can be completely shut down. This has cut electricity consumption by 700 kilowatt-hours (kWh) per month. In addition, the facility has been operating with solar water heaters for some time.

The company has installed 9-kilowatt (Kw) roof top solar units, which MacGillivray expects will cover most of the facility’s electricity needs. Glenergy is also in the process of developing a thermal storage system that will allow it to store and use this solar-generated electricity. “We are also anticipating cutting off our gas supply in the future,” notes MacGillivray. To achieve its energy independence, the company’s engineers are working in collaboration with members of the Queen’s University engineering department. Once the storage system has been commercialized, MacGillivray also sees residential applications for it.

MacGillivray says that, as a CIPEC Leader, his company will help support sound energy conservation policy. Moreover, he can share his company’s experience with energy efficiency and renewable solutions. He also hopes to partake in the networking opportunities and resources that CIPEC offers.

Independent Electricity System Operator (IESO) News

Case studies highlights their Industrial Accelerator Program enabled projects

“Many Ontario companies are leading the way in energy efficiency,” notes Jon Feldman, Sr. Technical Officer, Conservation for the Industrial Accelerator Program (IAP) at IESO. The IESO recently published a series of case studies that highlight these leaders and how IESO’s program has facilitated their projects.

The case studies demonstrate the range of opportunities from simple retrofits to re-designing processes for energy efficiency using IAP incentives. “They speak to the business benefits at the decision-making level,” says Feldman, who also notes that the case studies highlight the partnership aspect of the company-IESO relationship.

One of the case studies features Glencore Canada, which installed a new ventilation-on-demand system that is saving the company nearly $2 million annually at its Kidd mine in Timmins, Ontario. The new system uses an innovative WiFi system, occupancy sensors and booster fans to move air throughout the mine’s tunnels. More details on the project and the benefits can be found here: www.ieso.ca/-/media/files/ieso/document-library/iap/process-and-systems/6046-ieso-iap-glencore-casestudy-02.pdf?la=en.

ArcelorMittal Dofasco (AMD) also implemented many energy saving projects with support from the IAP. By taking a staggered approach to energy management, ArcelorMittal Dofasco redeploys incoming IAP incentives to start a new project. 

Thanks to incentives from the IAP, ArcelorMittal Dofasco is able to have a continuous cash flow for new projects. Since 2011, the company has completed nine projects with an additional two to be completed shortly, allowing the company to save 125,000 megawatt-hours (MWh) in recurring annual energy savings – an equivalent of $10 million annually. More details on AMD’s approach to energy management can be found here: www.ieso.ca/-/media/files/ieso/document-library/iap/process-and-systems/5718-ieso-industrialacceleratorprogram-casestudy-10.pdf?la=en.

Feldman mentions that the IAP is there to help when energy efficient projects are hampered by financial barriers. “Through capital incentives or other areas of support, the IAP team is dedicated to making projects become reality.”

For more information on the Industrial Accelerator Program, visit: www.ieso.ca/iap.

YouTube Channel videos highlight energy efficiency successes of Ontario businesses

The IESO recently released a series of Save on Energy YouTube channel videos that showcase the saving energy successes Ontario businesses have achieved.

Energy efficiency retrofits are still a main driver for businesses, but the unexpected benefits such as a safer work environment or the ability to better highlight products are becoming important considerations as well.

The video, Pillars of Efficiency, for example, highlights the benefits when behavioural, organization and technological changes converge. Such changes usually start with one person asking questions leading to a ‘chain reaction’. The changes become unstoppable and the benefits undeniable.

Why hire an energy manager? shows the benefits of hiring energy managers. “We are ambassadors of a lot of profit,” say the managers featured in the video. Energy managers are the easiest avenue for driving that profit. Money invested in an energy manager, is money well-invested.

The IESO YouTube channel features business success stories such as KI Canada.The video traces KI’s path from setting energy reduction goals to achieving annual energy savings of 30 percent. In addition to implementing retrofits, KI invested in educating its employees. Managers at KI estimate that at least $250,000 in annual savings is attributable to employee ideas.

The innovative energy saving measures implemented at Lear Corporation’s Ajax facility have made it a leader for Lear facilities around the world. The team at the Ajax facility has made significant improvements in its compressed air and lighting systems that have saved 1.46 gigawatt-hours (GWh) annually.

In another video, IESO highlights 3M Canada’s approach to saving 12 GWh annually. 3M Canada cites energy efficiency as a major factor for keeping their costs competitive and maintaining their workforce in Canada. Some of 3M’s measures include retrofitting equipment with variable frequency drives, updating to LED lighting and efficient HVAC systems. 

Smaller lighting upgrades at Valiant TMS have led to bigger projects like HVAC system and compressed air upgrades, which were then replicated in the company’s other facilities. The company now boasts a 25 percent reduction in annual energy consumption and an improved work environment.

Ontario businesses can Save on Energy as well – the program supports and encourages energy-efficient upgrades including lighting and HVAC to compressed air and building automation retrofits.

RETScreen contributes to energy savings at 3M Canada facilities

“Given that the big players are already using and benefitting from the RETScreen software, organizations that are not yet utilizing it could find themselves at a competitive disadvantage,” states Gregory Leng, Director, RETScreen International. One of the big players is 3M Canada, an organization that has been at the forefront of energy management in Canada.

“3M is a good example of the full deployment of RETScreen,” says Leng, noting that the company uses the software to determine project feasibility and to make the business case for capital investment, while it continues to explore other applications.

3M Canada operates seven manufacturing facilities in Ontario and Manitoba and employs about 1,800 people. Andrew Hejnar, Canada 3M’s Corporate Energy Manager, and his team have been using RETScreen software to identify an array of energy saving measures that have made 3M a national leader in energy management.

For example, Hejnar used RETScreen’s feasibility analysis module for the installation of a 2-megawatt (MW) combined heat and power (CHP) plant at the company’s Brockville, Ontario facility, reducing energy costs by about 30 percent annually. A 1.2 MW CHP unit being finalized for Perth, Ontario and a 1.5 MW CHP installation being constructed in London, Ontario are poised to multiply these savings.

The construction of these new facilities and the significant savings being generated are direct results of using the RETScreen software. “RETScreen allowed me to build business cases for all three projects,” says Hejnar. “Without RETScreen, the CHP projects would not have happened.”

Hejnar also sees RETScreen as a “fantastic tool for the design and monitoring part of the ISO 50001 standard.” In addition, he uses the RETScreen Performance Analysis Module for regression and CUSUM analysis to report savings to Ontario’s Independent Electricity System Operator (IESO) for other energy management activities at 3M Canada.

Currently, Hejnar and his colleagues are using the new RETScreen Expert software and are excited about its potential. Leng notes that RETScreen Expert is a major advance as it has built-in modules to measure and verify savings over the life of an investment. Moreover, the RETScreen allows organizations to integrate analyses and energy management for multiple facilities into one platform.

RETScreen developers are working with 3M to refine and modify the software to facilitate certification to such standards as ISO 50001 and the U.S. Superior Energy Performance (SEP).

Currently there are 555,000 users taking advantage of RETScreen because “it is a global standard on feasibility of energy projects and is growing on the measurement and verification side. Ultimately, RETScreen can help organizations meet their GHG emissions reduction goals and represents an essential productivity tool,” notes Leng.

Silfab Solar wins OSEA’s Powering Prosperity Manufacturer of the Year award

“We have sustainability built right into our vision,” says Geoff Atkins, Business Development, Sales, Marketing at Silfab Solar Inc. The company manufactures PV solar panels, and was recently recognized as Manufacturer of the Year by the Ontario Sustainable Energy Association (OSEA) through its Powering Prosperity awards.

Silfab’s 10,219 square-metre facility in Mississauga, Ontario, produces 300 megawatts of PV solar panels annually. Atkins explains that Silfab’s goal is to produce highly-efficient solar panels with the lowest possible ecological footprint.

The company achieves this in part with its “just-in-time” production model, which means solar panels are produced on an as needed basis, which eliminates the need for a large warehouse. Atkins says that this model allows Silfab to maximize its building footprint, while minimizing energy costs. 

Silfab’s sustainability vision is deeply engrained in all aspects of the company from employee awareness and the company’s policies to production and shipping. For example, Silfab regularly invests in upgrades to more energy-efficient equipment, has upgraded to LED lighting throughout its facility, has electric vehicle charging stations, recirculates building air to reduce heating/cooling costs and utilizes reusable corners and pallets for shipping.

In the future, Atkins says the company is looking into the installation of solar panels on the facility’s carport to further reduce electricity consumption. “We will continue to innovate in order to produce more solar panels in a sustainable manner.”

These initiatives and Silfab’s continuous commitment to sustainability is what its OSEA award celebrates. “We are proud to be recognized for our efforts and our vision with the Powering Prosperity award,” says Atkins. Nicole Rissie, OSEA’s interim Executive Director, says that Silfab won because “sustainability is reflected in everything they do.”

OSEA’s Powering Prosperity awards recognize excellence, innovation and best practices in the sustainable energy sector. To be considered for the awards, applicants submit projects implemented in Ontario within the last five years. Submissions also have to incorporate concepts such as sustainability, efficiency, community participation, and environmental stewardship. Nominations are evaluated by a panel of judges from the sustainable energy community. 

The Powering Prosperity awards are part of OSEA’s mission to promote ecologically sustainable communities across Ontario through stakeholder collaboration and raising public awareness. OSEA works to advise policy makers on sustainable energy issues and to encourage “energy literacy” within the general public. “With the power of collaboration we can champion the energy transition,” states Rissie.

For more information on OSEA, click here.

ABS Friction plans major energy efficiency measures

“ABS Friction has a busy year of energy efficiency projects ahead,” says Rupinder Dhaliwal, the company’s Plant Manager. These projects are in addition to the measures that have already been implemented over the past few years.

ABS Friction, a new CIPEC Leader in the general manufacturing sector, is a producer of disc brake pads for the automotive aftermarket. Its 11,148 square-metre facility in Guelph, Ontario, operates 24/7 year-round and employs 90 people.

“As a large manufacturing operation that uses heavy equipment such as dust collectors, air compressors and hydraulic presses, which contribute significantly to the facility’s energy bill, we are looking at every opportunity to reduce energy consumption,” says Dhaliwal.

Over the past two years and with incentives from Guelph Hydro, ABS Friction has undertaken a lighting retrofit for most of its facility, replacing T-12 with LED fixtures. Dhaliwal notes that motion sensors have also been installed and that lighting improvements will continue. The company also has compressor leak program, with a contractor identifying and repairing leaks in the system on a regular basis.

“We have several key projects on our to-do list,” says Dhaliwal, adding that many of them will be implemented over the next year. For instance, the company plans to retrofit some of its equipment (e.g. dust collectors and grinding machines) with variable frequency drives (VFDs).

One major project will be the replacement of the water chiller system with a rainwater collection system and an underground cistern for storing that water. Chiller water is required to cool the hydraulic loading presses used in the manufacturing process. The new system will reduce the company’s water consumption as well as its energy use.

Dhaliwal also has plans for a number of heat recovery measures as he sees multiple opportunities for energy savings. The heat generated in the compressor room and from the burners on the paint line, for example, is going to be captured to use for space heating.

Employees at ABS Friction have made numerous suggestions that have been implemented through the company’s employee suggestion program that welcomes ideas for process, equipment and energy improvements. Dhaliwal comments that his “company is guided by a strong sustainability philosophy and a CEO, who is an energy champion.”

New CIPEC Leaders

Food and Beverage Sector

Saputo Dairy Products Canada G.P.
- Georgetown, Ontario
- Ottawa, Ontario

Forest Products Sector

Cascades Emballage carton-caisse – Cabano, Témiscouata-sur-le-lac, Quebec

Mining Sector

Red Chris Development Company Ltd. – Red Chris Mine – Dease Lake, British Columbia

Calendar of Events

Call for story ideas

Has your company implemented successful energy efficiency measures that you would like to share with Heads Up CIPEC readers? Please send your story ideas for consideration to the editor, Jocelyne Rouleau, by e-mail at jocelyne.rouleau@canada.ca.

If you require more information on an article or a program, contact Jocelyne Rouleau at the above e-mail address.

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