Effbox Refrigeration Efficiency


1. Industrial Bakery freezers

Our client, an industrial bread bakery in West London was using 216 MWh per year on refrigeration for two of its freezers.

We were able to significantly reduce the energy consumption on their 1.4 MW ammonia system which comprised two Grasso screw compressors and an Evapco evaporative condenser, by the installation of Effbox to float and optimise the discharge pressure of the system.

Using industry standard regression analysis to target refrigeration electricity against both production and cooling degree days we were able to prove that after modifications energy consumption was in fact reduced by 11.2%. This provided ongoing electrical savings of 240,000 kWh or £20,500 per year. The project payback was less than 12 months.

The site’s Projects Engineer said

Improving energy and cost efficiency are important for us to remain competitive. We looked at numerous measures to reduce refrigeration energy before choosing Effbox due to its payback and simplicity.

It took the contractors one day to install with no down time and based on current data we expect to save about £20,000 per year. We plan to install two more on other plants in the coming months.

 

Statistics

  • Customer – Bakery UK, West London
  • Plant – 2 x 700kW Grasso S3 screw compressors, R717 Ammonia gas, Evapco evaporative condenser
  • Savings Achieved/Year – 240,000 kWh
  • Cost Saving/Year – £20,500
  • Return on Investment – less than 12 months

 

The Graph Below Shows Monitored Savings:

Bakery savings

2. Industrial Dairy Cold Store

Our Client, an industrial liquid milk dairy in North London was using 350,000 kWh per year one of its two cold store refrigeration plants.

We were able to significantly reduce the energy consumption on their 300 kW Sabroe system which comprised three Sabroe Single stage reciprocating compressors, with three individual air cooled condensers by the installation of variable speed drives for the condenser fans and Effbox to float and optimise the discharge pressure of each system.

Using industry standard regression analysis to target refrigeration electricity against both production and cooling degree days we were able to prove that after modifications energy consumption was in fact reduced by 7.5%.  This provided ongoing electrical savings of 26,000 kWh or £2,200 per year.  The project payback was 2.75 years.

The Engineering Manager said

 We have year on year corporate targets to reduce energy consumption and refrigeration is a big energy user for us. We have installed three of these units; they are working well and delivering the promised savings. This is a cost effective retrofit that I would recommend to others.

The Engineering Team Leader said

 These units have been installed at our site and are working very well

 

Statistics

  • Customer – UK Industrial Dairy
  • Plant – 3 x 100kW Sabroe Single stage recip, R422D gas, 3 x air cooled condensers
  • Project Cost – £6,000
  • Savings Achieved/Year – 26,000 kWh
  • Cost Saving/Year – £2,200
  • Return on Investment – 2.75 years

 

The Graph Below Shows Monitored Savings:

Dairy savings

Visit the Effbox website if you would like to find out more.


About Dan Jackson

Dan Jackson is a process and sustainability consultant. He has experience in helping clients reduce energy and cost in the NHS and across the hospitality supply chain, from breweries to pubs.