When Idaho Milk Products had the opportunity to design and build a new dairy processing facility in Jerome, ID, they set out to create a plant that would operate as energy and resource efficient as possible. Now the facility is estimated to save enough energy annually to power nearly 400 homes and has reduced wastewater effluent by 70%. This week Idaho Power awarded Idaho Milk Products a $97,000 cash incentive for their efforts in reducing energy consumption.
“We commend Idaho Milk Products on their impressive energy efficiency efforts and this well-deserved incentive,” commented Leo Sanchez, Key Accounts Energy Advisor with Idaho Power. “We look forward to our continued partnership as we help them reach their energy goals.”
Steps taken at the Idaho Milk plant to reduce energy demand and drive efficiency include:
PROCESSING PUMP VARIABLE FREQUENCY DRIVES (VFDs) The process has 24 pumps, which can be controlled with either a control/throttling valve or a VFD. This measure includes selecting VFDs on the pumps where either option is possible.
TWO-STAGE VARIABLE SPEED COMPRESSORS Two-stage compressors produce more air for the same power, allowing the compressors to operate at a lower percentage of full load. This measure also includes a cycling dryer instead of a non-cycling dryer.
LIGHTING This measure upgrades the plant lighting from a system designed primarily around metal halide fixtures to a system designed primarily with fluorescent T8 fixtures. Also, lighting controls are specified to turn off the lights when possible using occupancy sensors.
COOLING TOWER FANS AND CONTROL UPGRADES The refrigeration system provides chilled glycol to the plant. The system has four chiller packages and four corresponding cooling towers. This measure includes VFDs to control the cooling tower fans. Also, the control algorithms for sequencing the cooling towers and for determining the temperature control set point are modified.
BOILER FEED WATER PUMP VFDs The boiler feed water pumps are designed to provide the required pressure at the maximum flow rate. As the required flow decreases, the pump discharge pressure increases. By reducing the pump speed, the required flow can be provided without increasing the pressure above the minimum requirement.
Idaho Milk is continuously seeking new ways to save energy and investing in the reliability of their electrical system. This has reduced the impact from transient switching, surges, and frequency shifts. They also replaced fluorescent light bulbs rated at 40 watts per bulb with LED light bulbs rated at 16.5 watts per bulb. The annual energy savings totals over 1.3 million kWh. Idaho Milk also participates in the Idaho Power Flex Peak Program, which motivates participants to reduce their electric load during Idaho Power initiated demand response events, six times per year. This saves 1,200 kilowatts each time for an annual savings of 7,200 kilowatts.
Thanks to the energy savings and demand response measures, Idaho Milk estimates they save 4.2 million fewer kilowatt hours annually. Such savings are a prime example of how prudent investments in efficiency can quickly payoff and not only improve financial performance but also benefit the environment.