Driving Energy Efficiency in the Beverages IndustryFMA Future Facilities Summit 3 – May 2016

Andy Lempera

About PepsiCo…

• World leader in convenient snacks, foods and beverages• + $63 billion annual revenue• + 285,000 employees• Fortune 50 company

About me…• 6 years as resource conservation engineer at PepsiCo• BS in Mechanical Engineering from Purdue University 1999• MS in Energy Engineering from UIC 2010• 10 years as consulting mechanical engineer• PE in Illinois, LEED AP

Introduction

Agenda1. PepsiCo Energy Management

Program

2. Employee Engagement

3. Capital Projects

Introduction

PepsiCo Energy Management Program

PepsiCo Energy Management Program

1. Employee Engagement• Based on the ENERGY STAR model• Formalized by PepsiCo in 1999• Environmental task force formed in 2001• PepsiCo has been an ENERGY STAR

partner since 2007• Awarded the ENERGY STAR Sustained

Excellence Award every year since 2009

2. Capital Projects• Energy efficiency projects developed by

ReCon team• Project must meet IRR requirements to

receive capital

Employee Engagement

Employee Engagement

ReCon Group, November 2013 RC Audit, Beloit, WI

Global ReCon Team

Business Unit ReCon Team(Pepsi, Gatorade, Quaker, Frito-Lay,

Tropicana)

Plant RC Lead

Air Leak Manager

Depending on plant size…

HVAC Manager Boiler Manager

Water Manager Gas Manager

Electricity Manager

(corporate team consisting of ~10 members + business unit

leads)

ReCon teams

Employee Engagement

Partner with maintenance teams• Critical to successful RC program

• The best energy efficiency project in the world isn’t worth anything if it isn’t properly maintained

• Savings from a new capital RC project can be wiped out if the rest of the plant is not operating properly

Employee Engagement

Good, bad and ugly levels of employee engagement

• Takes weekly meter readings, attends monthly review calls

• Compressed air leak audits 2/yr (target <10% of total airflow)

• Monitor compressed air plant/refrigeration plant efficiency (kW/100cfm, kW/ton)

• Waste heat energy recovery from compressors to make-up air

• Vent condensers – Cedar Rapids, IA

• Daily walk-throughs (production area, mechanical room, roof!)

• Take monthly meter readings, don’t attend monthly review calls

• Contractor installed pressure relief valves instead of expansion tanks

• HVAC economizers not working

• BAS not working

• Installed desiccants for process that only requires 40°F dew point

• Hard piped condensate directly to drain instead of fixing steam traps

• Nearly installed refrigeration system to cool process down to 90°F

• Installed air-cooled process chiller inside an air-conditioned building

Capital Projects

Capital Projects

1. Condensing Economizers• Captures latent heat from products of combustion• Improve boiler plant efficiency from ~82% to ~95%• Must have heat sink < 140°F• Installed at nearly all plants with large heat sink

2. Biogas Cogeneration• Landfill gas driven reciprocating engine• Provides electricity for the plant• Provides ~160°F hot water for process• Provides 100 psig steam for process

Capital Projects

3. LED Lighting• Replacing fluorescents• Draws a % of power as fluorescents while

providing same or greater lumens

4. Compressed Air Plant Upgrades• High speed magnetic bearing centrifugal

compressors• Piping modifications to reduce pressure drop• Oversized filters• Controller to avoid running compressors

unloaded

Before After

Capital Projects

5. Steam Trap Upgrades• Replaced mechanical traps with dynamic orifice

traps• Removed condensate pumps and lift

condensate using steam pressure• 10 year warranty

6. Insulating blankets• Removable blanket insulation• Provides energy savings for equipment typically

too difficult to insulate such as valves, heat exchangers, condensate receivers

Capital Projects

7. Flash tanks• Capture flash from high pressure condensate

and use as low pressure steam• Saves water and fuel

8. VFDs• Use for modulating loads• Power consumption % = (%speed)3

• Don’t use for balancing only… trim pump impeller or resheave blower

Summary1. PepsiCo Energy Management Program

• Follow Energy Star method to engage employees

• Run capital projects

2. Employee Engagement• Create teams (include maintenance

personnel)• Get ahead of future projects• Audit plants

3. Capital Projects• Heat recovery• Compressed air improvements• Cogen• VFDs• Steam trap upgrades• Insulate & fix leaks

Summary

Driving Energy Efficiency in the Beverages IndustryFMA Future Facilities Summit 3 – May 2016

Andy Lempera

QUESTIONS?