Cott Beverages - Enbridge Gas Distribution

CG.029.8157 ECG Cott Casestudy
case study
A publication
from Enbridge Gas
Distribution
for Industrial
Energy Users,
providing information
on technology,
programs and
services.
2/12/03
10:11 AM
Page 1
At Cott Beverages Canada, Energy
Savings Go Hand in Hand with Safety
Cott Beverages Canada follows Enbridge Gas Distribution’s
energy audit recommendations to dramatically improve indoor
air quality, comfort, and energy efficiency.
At A Glance:
• Excel 500 building automation system saves 180,000 m3 in natural gas annually (valued at
$45,000 to $54,000). With the full package, Cott will save an anticipated 25% in fuel bills.
• Natural gas forklifts allow operators to perform “opportunity refueling”, topping up whenever
near the station to save time.
• CO level reduced to 35 ppm or less, in compliance with Ontario’s safety regulations.
• Heating system improvements resulted in a comfortable, draft-free work environment.
Comfort and safety
issues prompt an
energy audit
Cott Beverages Canada in
Mississauga bottles and ships
millions of cases of soft drinks,
new age beverages, iced teas,
and bottled water per year.
The facility comprises 220,000
square feet of production, warehouse and office space. The
plant had a heating system
update in the nineties, but continued to experience problems with
cold and drafts. Negative air
pressure contributed to higher
than optimal heating costs. The
use of forklifts fuelled with
propane raised health and safety
concerns and placed added
demands on the air exhaust system in order to meet regulations
for CO levels.
In early 1999 Cott asked
Enbridge Gas Distribution
to perform a complete
energy audit.
Objectives:
• Reduce forklift fumes and
CO levels;
• Increase comfort and reduce
heating costs;
• Achieve long-term energy
efficiency;
As Csaba Reider, Vice President
of Canadian Operations for Cott,
puts it:
“Safety is always number one.
Once safety is taken care of,
because we are a low-cost
manufacturer we have to turn
over every stone, and that
includes energy conservation.
Not just for today as we
weren’t looking for a quick fix.
We wanted long-term energy
management put in place with
alternatives suggested by
Enbridge Gas Distribution.”
• Position the company to meet
Kyoto targets for greenhouse
gas emissions.
Enbridge Gas
Distribution facilitates
an integrated solution
Cott Beverages Canada’s flagship facility in Mississauga. Cott is using
the Enbridge Gas Distribution blueprint for integrated energy solutions
for its other plants across Canada.
The Enbridge Gas Distribution
energy audit recommended
a set of integrated solutions.
They also acted as a facilitator.
They brought in Honeywell Ltd., a
trusted design/build contractor,
to do a detailed feasibility study
of the heating and ventilation system. They also contacted
FuelMaker Corporation, the world
leader in on-site natural gas refueling systems, to assess the economics of converting the forklifts
to natural gas. Enbridge Gas
Distribution helped facilitate this
feasibility study by contributing
CG.029.8157 ECG Cott Casestudy
2/12/03
10:11 AM
Page 2
2/3 of the total cost of the audit,
a value of $5,000. Honeywell recommended installing booster
heaters on existing roof-top units to
provide more heat where it was
needed. They also suggested a
building automation system to balance heating and ventilation and
control CO levels.
case study
FuelMaker Corporation
estimated that Cott could save
between 25% and 47% on forklift
fuel costs by changing from
propane to natural gas.
For further energy savings
Enbridge Gas Distribution
recommended converting an electric
vapourizer to natural gas and contracting out energy sourcing.
Acting on the
recommendations
Cott Beverages decided to act on
all of the recommendations. They
contracted Honeywell to install
four boosters to the make-up air
units and proceed with the installation of an Excel 500 building
automation system.
Forklifts can refuel in two minutes at the FuelMaker natural gas station.
Cott replaced twelve of its sixteen
forklifts with natural gas vehicles
and the others are scheduled for
changeover as leases expire.
FuelMaker put in a Fast Fill fueling
station. The installation was completed in three to four days with
no interruption in production.
The heating system and fork-lift
changes work hand in hand to significantly reduce CO emissions
being produced. Cott has been
able to reduce the ventilation rate
and still improve air quality.
Cott also converted the electric
vapourizer to natural gas and they
contracted out their energy sourcing. The package of measures
has increased the company’s
overall energy savings and put it
in a good position to respond to
emission targets under Canada’s
Kyoto commitments.
Richard Paterson of Honeywell
Ltd. and Daniel Chum, Energy
Solutions Consultant for Enbridge
Gas Distribution check out the
Excel 500 building automation
system.
CG.029.8157 (REV. JAN/03)
Cott Beverages Canada is repeating the energy audit exercise in
its other Canadian plants using
what Reider calls the Enbridge
Gas Distribution blueprint.
An energy efficiency
grant from Enbridge
Gas Distribution
Enbridge Gas Distribution awarded Cott Beverages an energy efficiency grant of $9,021 based on
the estimated annual savings from
the building automation system.
case study
For more information
on these programs and
services, contact Enbridge
Gas Distribution at:
Phone:
1-866-844-9994
Fax:
(416) 495-8350
Website:
www.enbridge.com/business
E-mail:
[email protected]