Heads Up CIPEC – Volume 22, Number 1

Table of Contents

Mars Food sets out ambitious sustainability plan

“We are worried about climate change and the ability of the world to move fast enough,” says Barry Parkin, Mars Food’s Chief Sustainability Officer. That worry has translated into action at all levels of the organization and at its facilities around the globe. The company is investing $1 billion in cutting greenhouse gas emissions across its facilities by two-thirds by 2050.

Mars Food is a manufacturer of confectionery, pet food, and other food products and a provider of animal care services. Globally, Mars has invested in renewable energy and is using or has purchased enough renewable energy to run many of its factories. Moreover, Mars plans to make all of its nearly 150 factories around the globe carbon neutral by 2040.

One of those facilities is located in Bolton, Ontario, which specializes in the production of confectionery, pet food, and instant rice. The new plant features energy efficient lighting, cooling and boasts lots of natural light. Its south-facing windows actually create some passive solar heating, notes Dave Dusangh, General Manager at Mars Food, Canada.

Dusangh notes that the manufacture of instant rice consumes significant quantities of energy in the boiling of water. A few years ago, this process was analyzed and solutions implemented. Water that was used only once in cooking rice is now cleaned and re-used in the rice boiling process. With this recirculation system, the factory has reduced its water consumption by 85 percent.

With less water use, also comes a reduction in energy use. In fact, the plant has reduced its energy consumption by two-thirds less per year compared to eight years ago.

Parkin says that being energy efficient and using renewable energy is simply good business. Sustainability is part of the way Mars does business and sustainability for the company goes even further. For Mars, sustainability also includes treating its supply chain equitably from an environmental, economic and social perspective.

NB Power’s incentives offer energy saving opportunities

“The Energy Smart Industrial Program helps industry achieve significant energy savings and productivity gains with a variety of financial incentives and programs,” says Beth Pollock, Program Delivery Manager at NB Power.

Pollock explains that NB Power offers incentives for all sizes of industrial organizations and all sectors of industry. “We have tailored our support for our customers depending on their needs and the size of their business and energy consumption.”

Small industry customers—those with a rate schedule lower than 750 kilowatt (kW) of contracted demand and consumption of less than 500 Megawatt hours (MWh) annually – qualify for up to $10,000 towards energy assessments and up to $115,000 for upgrade implementation.

Customers consuming more than 500 MWh annually and a rate schedule lower than 750 kW of contracted demand are eligible for a maximum of $10,000 for energy assessments and up to $135,000 for implementation of projects.

Organizations that consume 7,000 kW or more of demand and have a rate schedule of 750 kW or more of contracted demand, can take advantage of NB Power’s assessment, upgrade and Energy Management Information System (EMIS) incentives. Moreover, large industrial customers can receive up to $20,000 for energy assessments, a maximum of $150,000 for project or EMIS implementation.

For all of its industrial clients, Pollock notes that NB Power offers financial support for energy audits for companies new to energy efficiency upgrades and feasibility studies to help evaluate retrofit measures already identified.

In addition, NB Power offers the Custom Incentive option for companies planning to undertake larger energy efficiency upgrades. With this program, the incentive is either $30/gigajoule (GJ) saved or 50 percent of the cost to a maximum of $150,000.

NB Power also gives its biggest customers - those with an average monthly demand of 2 MW or more - incentives to implement an energy management information system (EMIS). This program provides 50 percent funding for EMIS audits, design, implementation and optimization.

Pollock explains that funded projects include process upgrades, HVAC systems, refrigeration, lighting and controls, and compressed air systems and that, to date, industrial sectors, such as general manufacturing, forestry, and mines have participated in the Energy Smart Industrial Program offering.

Frogpond Farms puts sustainability first

“We grow organic because we believe our production methods need to be more sustainable to ensure that future generation can live a liveable life,” says Jens Gemmrich, owner of Frogpond Farms.

Frogpond Farms is an organic winery located near Niagara-On-The-Lake, Ontario. Its wine production facility is about 230 square meters with the vineyard covering about 12 hectares. Operational since 2001, Frogpond Farms is Ontario’s first certified organic winery, which follows strict guidelines that foster a sustainable ecological cycle on the farm. This also includes a focus on using energy resources wisely, says Gemmrich.

Gemmrich notes that one of the first energy efficiency measures that was implemented with the construction of the production building was the use of high R-value insulation. “We can’t afford to waste any energy, so good insulation was an obvious choice.” He adds that with the heat generated from the fermentation of the grapes and the insulation, there is no need to heat the building for the duration of the production period, which lasts into November.

The production building also features LED lighting, which has reduced electricity costs significantly. To conserve transportation fuel use, Gemmrich tries to combine shipments of his wines. Moreover, Frogpond subscribes to Bullfrog Power, which provides the company with clean, renewable power.

In terms of water conservation, Gemmrich notes that to date rainfall is sufficient to eliminate the need for irrigation. Equipment cleaning requires the most water and future projects may include looking at measures to reduce process water consumption, such as capturing rain water.

“We want to stay away from non-renewable energy sources as much as possible,” says Gemmrich. To that end, Frogpond Farms is minimizing its use of natural gas for heating. Furthermore by adhering to organic standards, fossil-fuel derived pesticides and fertilizers are also not used.

Kruger invests in energy efficiency and product diversification

“Our goal is simple—to position Kruger as a leader in energy efficiency within the sector,” says Maxime Cossette, VP, Environment, Health and Safety at Kruger Inc. To achieve this, the company has a corporate target to reduce by 10 percent its energy consumption and by 12 percent its GHG emissions by 2020 compared to 2015. With numerous projects already in place and more to be implemented shortly, Kruger is well on its way.

One recent project was the reconstruction of a newspaper machine at its Trois-Rivières plant to a high-quality, recycled cardboard machine. The new machine features the latest, most energy efficient drying system. A few years earlier at the same plant, the redesign of the thermomechanical pulp effluent system allowed for electrical savings of 105,670 GJ annually.

Significant improvements to the heat recovery system at the Gatineau Kruger facility were made by using low-pressure steam from the condensate produced by dryers in its production lines. In addition, a cleaning shower has been installed that uses high-pressure, hot water that is produced by another heat recovery process. Both projects have reduced natural gas and bunker oil consumption significantly.

Kruger’s Crabtree plant has implemented a number of projects including lighting and compressed air retrofits that have saved it nearly 10,000 MW annually and allowed for membership to Hydro-Québec’s prestigious Ecoelectric Network.

Kruger has a corporate energy efficiency team that conceives and implements these projects and others that reduce electrical and thermal energy as well as water consumption and GHG emissions.

“We are acutely aware of the fact that the longevity of our business is intimately related to the sustainable management of our resources,” says Cossette. This is why the company integrates eco-responsibility in all that it does from production processes to procurement to product delivery.

In addition to its energy efficiency initiatives, Kruger is also on a path of diversification. The company is investing heavily in production for growing markets such as sustainable food packaging. Kruger Energy, the company’s energy business unit, is also updating its 23 MW cogeneration plant at Brompton, Québec.

Manitoba Hydro’s palette of energy efficiency incentives and rebates for industry

Manitoba Hydro offers a gamut of energy efficiency incentives and rebates to its industrial customers. The utility provides low-cost and no-cost evaluations as well as technical support with targeted energy measures.

To reduce natural gas consumption and optimize its use, Manitoba Hydro offers incentives and support for both feasibility studies and implementation of efficient process related natural gas-fired equipment and systems.

Manitoba Hydro clients who want to optimize their electro-technology processes and motor-drive systems can apply for financial incentives through the Performance Optimization Program. The utility offers technical support for feasibility studies of such optimization projects.

Industrial facilities are eligible for no-cost energy efficiency screening studies, which identify energy efficiency potential and Power Smart saving opportunities. Manitoba Hydro also offers Power Smart Lean to organizations that already follow lean manufacturing principles.

In addition, Manitoba Hydro provides technical expertise and financial assistance for engineering studies that will lead to increased productivity through the Eco-efficiency Solutions Program. Large business customers can also work with utility experts as part of the Lighting studies program to identify potential energy savings opportunities and productivity improvements associated with lighting.

Moreover, Manitoba Hydro actively promotes alternative energy to its customers. Participation in the Geothermal Program, for example, allows organizations to significantly cut their heating, cooling, and water heating costs with the installation of energy efficient and environmentally friendly geothermal heat pumps.

The Bioenergy Optimization Program supports organizations in projects that convert waste streams and by-products into fuel that can provide heat and power. Additionally, through the Solar Energy Program, Manitoba Hydro pays $1 per eligible watt of power generated from a newly installed solar photovoltaic system.

There is more. Manitoba Hydro’s HVAC Program is another incentive that helps customers retrofit their heating, ventilation, and cooling systems for more energy efficient systems, thus substantially reducing maintenance and operating costs.

Manitoba Hydro also offers a number of unique programs including incentives for Agricultural heat pads, which can replace traditional heat lamps for significantly lower annual energy and maintenance costs per year.

For more information about specific incentives and rebates offered by Manitoba Hydro, visit https://www.hydro.mb.ca/your_business/savings_business.shtml.

Industry events and resources

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