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What’s cooking withWhat s cooking with ENERGY STAR?
BC&MA Annual Technical ConferenceKansas City, MO
May 7 2013May 7, 2013Walt Tunnessen
US EPA ENERGY STAR Programg
AgendaAgenda
• Introductions • Background on ENERGY STARBackground on ENERGY STAR• Specific Resources for Bakers • Benchmarking Cookie & Cracker Bakeries• Earning the ENERGY STAR• Earning the ENERGY STAR• ENERGY STAR Challenge for Industry• Engaging sites
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IntroductionsIntroductions
• Who are you?
• Where do you work?
• What’s your role in energy management?• What s your role in energy management?
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ENERGY STARENERGY STAR• Voluntary government programVoluntary government program
– Established by EPA in 1992– Helps companies achieve their best in energy efficiency– Provides a cost effective strategy to reduce GHG emissionsProvides a cost effective strategy to reduce GHG emissions
• THE national symbol for energy efficiency– Awareness exceeds 80%Awareness exceeds 80%– Brand owned & managed by federal government
• Helps industry to build strong energy management programs andHelps industry to build strong energy management programs and recognizes successes
• Industry participatesy p p– Over 700 industrial corporations are partners– Over 18 specialized industrial sectors address their energy
management issues with the programmanagement issues with the program
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The ENERGY STAR approachThe ENERGY STAR approach
Effective energy management practices
++Strong company energy programs
+Organizational culture focused on efficiencyOrganizational culture focused on efficiency
= Continuous energy performance improvement
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ENERGY STAR for Buildings & PlantsENERGY STAR for Buildings & Plants
ENERGY STAR works with companies to develop stronger energy management programs by offering:
Instructive Partnership ProgramENERGY STAR Guidelines
for Energy Management Instructive Partnership Program
Energy Management Guidance
for Energy Management
Energy Program Resources
Benchmarking & Tracking ToolsBenchmarking & Tracking Tools
Recognition Opportunities for Achievements
Sector Specific Tools & Resources
ENERGY STAR helps companies build a culture f d ffi ifocused on efficiency.
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The ENERGY STAR Partnershipp
• Companies can partner with ENERGY STAR.
O 00 f h j i d h• Over 700 manufacturers have joined the ENERGY STAR partnership.
• Partnering offers more opportunities to leverage ENERGY STAR resources and helps g pa company.
• Companies join at the Corporate level.
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Building an effective programBuilding an effective program
ENERGY STAR’s ENERGY STAR Guidelines forENERGY STAR s Guidelines for Energy Management
ENERGY STAR Guidelines for Energy Management
– A framework for how to develop an energy program
– Based on best practices from successful ENERGY STAR partner companies.
– Structured on a “plan-do-act-check” approach. Informed the ISO 50001 standard.
– The foundation for the energy programs of thousands of organizations in the U.S.
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Assistance for specific industriesAssistance for specific industries
For specific sectors EPA convenes “Industrial Focuses”For specific sectors, EPA convenes Industrial Focuses
Key outcomes include:
Energy Guide that identifies energy efficiency opportunities.
Energy Performance Indicator (EPI) to benchmark performance of plants in the sector
Sharing of best practices
Networking among sector’s energy managersg g gy g
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ENERGY STAR Industrial Focuses
FocusPeer Exchange Industrial Energy Energy Performance Focus Exchange Network Guide Indicator
Cement Manufacturing Published 2nd Version Released Concrete Published In development
Commercial Baking• Cookies & Crackers• Breads & Baked Goods Published Released
In development • Breads & Baked Goods In development
Corn Refining Published 2nd Version Released Dairy Processing Fluid dairies Cheesemaking Ice Cream
Published Draft
Food ProcessingFood Processing Juice Potato Products Tomato Products
PublishedReleasedReleased
Draft
Glass Manufacturing DraftGlass Manufacturing Fiberglass Flat glass Container glass
PublishedDraft
ReleasedReleased
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ENERGY STAR Industrial focuses –cont’d
PeerFocus
Peer Exchange Network
Industrial Energy Guide
Energy Performance Indicator
Motor Vehicle Manufacturing P bli h d 2nd Version Released Manufacturing Automobile Assembly Plants Power train Plants
Published 2 Version ReleasedIn development
Metal Casting In process Draft (iron)
Petrochemical Manufacturing Published Draft
Petroleum Refining Published Private system recognized by EPA g recognized by EPA
Pharmaceuticals Published Released
Printing In process Exploring OptionsPrinting In process Exploring Options
Pulp & Paper Integrated Mills Pulp Mills
Published ReleasedReleased
S l
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Steel Primary Steel Mini Mills
Published DraftDraft
Specific Resources for BakersSpecific Resources for Bakers
C ki & C k B k i• Cookies & Cracker Bakeries– Plant Energy Performance Indicator (EPI)– ENERGY STAR Certification – ENERGY STAR Challenge for Industry– Energy Efficiency Savings Guide
Best Practice & Networking with ENERGY STAR Food Sector Focus– Best Practice & Networking with ENERGY STAR Food Sector Focus
• Commercial Bakeries– ENERGY STAR Challenge for Industry– Energy Efficiency Savings Guide
B t P ti & N t ki ith ENERGY STAR F d S t F– Best Practice & Networking with ENERGY STAR Food Sector Focus – Plant Energy Performance Indicator (EPI) in development
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Baking Energy GuideBaking Energy Guide
Contents:• Process energy flows and use• Energy management strategiesEnergy management strategies• Electric and thermal systems• Non-capital measures, short-payback
d it l j tmeasures, and capital projects• Common plant systems (motors, lighting,
boilers, compressors, etc. )• Bakery specific systems (ingredient
handling, mixers, conveyors, ovens, etc.)• Refrigeration systems• On-site generation
www.energystar.gov/energyguides13
Example: No capital improvementsExample: No capital improvements
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Example: Short payback periodsExample: Short payback periods
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Example: Capital ProjectsExample: Capital Projects
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Using the Energy GuideUsing the Energy Guide
• Identify potential projects & measures.
• Evaluate payback and savings estimates on proposed projects.proposed projects.
Train new and existing employees engaged in• Train new and existing employees engaged in energy management.
• Use to establish best practice standards.
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Benchmarking & Tracking ToolsBenchmarking & Tracking Tools
ENERGY STAR offers tools to help companies benchmark and trackENERGY STAR offers tools to help companies benchmark and track their energy performance:
Energy Tracking ToolEnergy Tracking Tool– Helps establish production based energy intensity metrics, set goals, and track
performance. Can be used by any type of facility. Spread sheet platform.
P tf li MPortfolio Manager– Scores the energy performance of selected commercial buildings and
warehouses. Web-based energy tracking system for buildings.
Plant Energy Performance Indicators (EPIs)– Scores the energy performance of specific industrial sites against the sector
nationally. Spread sheet platform
www.energystar.gov/industrybenchmarkingtools
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Assessing Plant Energy PerformanceAssessing Plant Energy Performance
ENERGY STAR Energy Performance Indicators (EPIs):ENERGY STAR Energy Performance Indicators (EPIs):
• Sector-specific energy benchmarking tools for industrial sites.
• Compare the energy efficiency of a plant against the performance of the industry.
• Based on annual energy use and production (energy intensity).
• Normalized for product mix, size, location, and other factors.
• Establishes an energy performance scale for the industry.gy p y
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How EPIs are developedHow EPIs are developed• Based on data reported to the US Census and/or• Based on data reported to the US Census and/or
provided by companies participating in the Focus.
• Researchers at Duke University use this data to determine statistically significant impacts, establish baselines, and develop a statistical model of the sector’s , penergy performance.
• A statistical model is used to “normalizes” for statistically• A statistical model is used to normalizes for statistically significant differences between plants and to prevent any disclosure of confidential company data.
• The EPI (model) is tested by industry representatives and revised (as necessary) based on industry feedbackand revised (as necessary) based on industry feedback.
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The Cookie & Cracker EPIThe Cookie & Cracker EPI
Wh t it dWhat it does:• Compares your plant’s energy
f i t th i d t i ’performance against the industries’.
• Rates your plants on scale of 1 to 100.
• Provides scenarios for average & efficient plants based on your production characteristics.
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Basic requirementsBasic requirements
• You must make cookies and/or crackers.
• 50% of total production must be cookies d/ k t th ENERGYand/or crackers to earn the ENERGY
STAR.
P d ti b t b i d• Production numbers must be in pounds.
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What do you mean by ?What do you mean by…?Crackers:Crackers:• Crackers, biscuits, and related products (NAICS 3118212)• Graham crackers (NAICS 311821 1331)• Saltines (NAICS 311821 1111)• Cracker meal and crumbs (NAICS 311821 1341)
Lower moisture content!• Cracker meal and crumbs (NAICS 311821 1341)• Cracker sandwiches (NAICS 311821 1221)• Other crackers and related products (sponge, sprayed, low sugar biscuits, melba toast, unsalted
soda crackers, taco shells, etc.) (NAICS 311821 1391)
Cookies: • Sandwich cookies (NAICS 311821 4111)• Marshmallow cookies (NAICS 311821 4331)• Creme-filled cookies (NAICS 311821 4341)Creme filled cookies (NAICS 311821 4341)• Chocolate chip cookies (NAICS 311821 4221)• Oatmeal cookies (NAICS 311821 4351)• All other cookies and wafers (NAICS 311821 4361)
Broad Categories – find the best fit. No Frozen products. Toaster Pastries, cereal bars are currently not included.
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Annual ProductionAnnual Production
Before entering data into the EPI, you will need to:
• Determine the 12 month period you will use.• Sum all cookie products in thousand lbs• Sum all cookie products in thousand lbs.• Sum all cracker products in thousand lbs.• Make marshmallow cookies? Calculated the %
of total cookie production based lbs. (thousands)
Marshmallows are more energy intensive!gy
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“Other” ProductsOther Products
Th EPI dj t f th d ti f “ th d t ”The EPI adjusts for the production of “other products” besides cookies/crackers:
• Based on the share (%) of other products produced BUT is calculated based on dollar value:
1. Determine the total $ value of all products produced2. Determine total $ value of all cookies/crackers or “other”
products (e g cereal bars)products (e.g. cereal bars)3. Calculate the % that other represents
E.g. “% other” = Sum (All Products-Cookies)/All Products
• Enter the % share (0 to 100) in EPI
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Energy dataEnergy data• Gather all utility bills invoices and other purchasing records• Gather all utility bills, invoices, and other purchasing records.
– Propane used for fork lifts is not usually counted.
• Determine annual electric natural gas oil etc use• Determine annual electric, natural gas, oil, etc. use.
• Purchased or transferred steam or compressed air must counted. Thi i ti th h d tilit t MMBTU f St kWh f– This requires converting the purchased utility to MMBTUs for Steams or kWh for compressed air.
– You will need to obtain conversion efficiency from your vendor.– E.g. 100 SCFM compressed air x 0.2 kW/SCFM x 4800 hours (per year)E.g. 100 SCFM compressed air x 0.2 kW/SCFM x 4800 hours (per year)
= 96,000 kWh
• Energy Cost data is optional
• Water utility data is not accounted for.
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EPI – Production & Energy InputsEPI Production & Energy Inputs
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EPI – ResultsEPI Results
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Cracker & Cookie EUI distributionCracker & Cookie EUI distribution
‐ 5.00 10.00 15.00 20.00 25.00 30.00
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Interpreting Resultsp g
High scoringHigh scoring sites provide
lessons learned and label
RCx & O&M improvements
yield savings and l b l did t
Best investment opportunities are in lower quartiles -greatest potential for
i t a d abecandidates label candidatesimprovement
Reward &
InvestTune
Reward & LearnInvest &
TInvest Tune
1 100755025Energy Performance Score 30
ENERGY STAR CertificationENERGY STAR Certification
Requirements:Requirements:
• Site must be in the United States (includes (territories)
• 50% of production is Cookies &/or Crackersp
• Energy Performance Score of 75 or higher
• No major Clean Air Act violations within the past 3 years of application– High Priority Violation (HPV) + large fineHigh Priority Violation (HPV) large fine
• No criminal conviction for an environmental crime within past 5 yearsp y
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Verification ProcessVerification Process
Two Step verification process for applying for ENERGYTwo Step verification process for applying for ENERGY STAR:
Step 1 - Data Integrity & Accuracy CheckInternal review conducted at the site or within the companycompany.
Step 2 – EPI Integrity & Accuracy CheckExternal review conducted off site.
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Step 1: Data Integrity & AccuracyStep 1: Data Integrity & Accuracy
– A PE must verify that data used in EPI is accurate and from documented sources.
– PE must stamp and sign the Statement of Energy Performance (SEP) which is in the EPIPerformance (SEP) which is in the EPI.
The reviewing PE can be from your company– The reviewing PE can be from your company
Th i d SEP i t t EPA ith th li ti– The signed SEP is sent to EPA with the application materials.
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Step 2: EPI Integrity & AccuracyStep 2: EPI Integrity & Accuracy
The results in your EPI must be replicated by either EPA orThe results in your EPI must be replicated by either EPA or our 3rd Party Reviewer.
• For EPA Review: Send a copy of the EPI to Rebecca Hindin at ENERGY STAR.
• For 3rd Party: Send a copy of the EPI to Gale Boyd at Duke University ([email protected])
If data is considered CBI, send to Duke University. EPI i t t D k U i d t d EPI copies sent to Duke Univ. are destroyed once score
is verified.
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Application materialsApplication materials
• Request application materials by contacting Rebecca Hindin at EPA –gENERGY STAR
Hindin rebecca@epa gov– [email protected]
• Have questions about compliance status?– Contact Rebecca.Contact Rebecca.
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The ENERGY STAR AwardThe ENERGY STAR Award
O li ti i dOnce your application is approved, you receive:
• Certification labelCertification label• Graphic templates for Flags, Banners,
etc.• Letter to CEO• Profile on ENERGY STAR web site • Communication materials to help
promote achievement.
The ENERGY STAR is an annual award!
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Rules about the ENERGY STARRules about the ENERGY STAR
The ENERGY STAR is awarded to a facility not its The ENERGY STAR is awarded to a facility, not its products or the company as a whole.
You can communicate your site is best in class for energy efficiency.
You can’t say your cookies are ENERGY STAR certified
You can and should publicized that your site earned the ENERGYSTAR.
If you want to communicate earning the ENERGY STAR for your site on your product, contact us first!y y p ,
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Certified PlantsCertified Plants
ENERGY STAR Labeled Buildings as of April 16, 2013
Plant Name Owner City State Label Year(s)Ashland Plant Snyder's - Lance, Inc. Ashland OH 2010Augusta Bakery Kellogg Company Augusta GA 2012, 2010Bremner Food Group - Poteau, OK Ralcorp Holdings, Inc. Poteau OK 2010Bremner Food Group - South Beloit, IL Ralcorp Holdings, Inc. South Beloit IL 2010Bremner Food Group - Tonawanda, NY Ralcorp Holdings, Inc. Tonawanda NY 2010p p gCary Bakery Kellogg Company Cary NC 2012, 2010Charlotte Bakery Kellogg Company Charlotte NC 2012, 2010Cincinnati Bakery Kellogg Company Cincinnati OH 2012, 2010Columbus Bakery Kellogg Company Columbus GA 2012 2010Columbus Bakery Kellogg Company Columbus GA 2012, 2010Florence Bakery Kellogg Company Florence KY 2012, 2010Lance Private Brands Snyder's - Lance, Inc. Burlington IA 2010Lance Private Brands - Columbus Bakery Snyder's - Lance, Inc. Columbus GA 2010Louisville Bakery Kellogg Company Louisville KY 2012, 2010North Sioux City Interbake Foods Inc. North Sioux City SD 2011Oak State Products Inc. Oak State Products, Inc. Wenona IL 2012, 2010Pulaski Manufacturing Facility Frito-Lay Inc. Pulaski TN 2011Pulaski Manufacturing Facility Frito Lay Inc. Pulaski TN 2011Richmond Baking of Indiana Richmond Baking Company Richmond IN 2010
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What if we don’t qualify?What if we don t qualify?
S t l t hi th• Set a goal to achieve the ENERGY STAR in the future.
• Take the ENERGY STAR Challenge for Industry:Challenge for Industry:– Recognition for 10%
reduction in energyreduction in energy intensity.
t /i d t h llwww.energystar.gov/industrychallenge
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Challenge for IndustryChallenge for Industry
What does it recognize?
10 % improvement in energy intensity within 5 years or less.
Calculated against an internal baseline at an industrial siteat an industrial site.
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Who can participate?Who can participate?
A f t i it t k th Ch ll• Any manufacturing site can take the Challenge.– No offices or warehouses.
• International sites of ENERGY STAR Partner companies can take the Challenge.
• To get official recognition, the site’s parent company must be (or become) an ENERGY STAR partner.STAR partner.
– A site is permitted to take the Challenge first, and their company can become an ENERGYand their company can become an ENERGY STAR partner at a later date.
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How it worksHow it works
Sites participate by:• Selecting an energy intensity metricSelecting an energy intensity metric• Establishing a baseline.• Setting a 10% improvement in 5
years goal.yea s goa• Registering for the Challenge. • Verifying savings if goal is achieved.
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What you getWhat you get
C tifi t• Certificate
• Communications materials• Communications materials
• Profile on energystar gov• Profile on energystar.gov
• Congratulations to CEOCongratulations to CEO
• Bragging rightsgg g g
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Why take the Challenge?Why take the Challenge?• Creates an objective for your energy program and• Creates an objective for your energy program and
sites.
• Reinforces energy management best practices• Reinforces energy management best practices.
• Opportunity to link your energy efforts to ENERGY STAR and a broader campaignSTAR and a broader campaign.
• Opportunity to leverage the ENERGY STAR brand in communicating your accomplishmentcommunicating your accomplishment.
• Opportunity to gain recognition for your achievements.
• Demonstrates leadership by setting a goal.
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The Fine PrintThe Fine Print• ENERGY STAR is a voluntary program; there are
no legal commitments.
• Achievements are rewarded when you report• Achievements are rewarded when you report them to us. No annual reporting is required.
• If a site does not achieve the Challenge, you are not penalized.
• To make your reduction credible, a professional engineer (PE) must verify it.
• To be recognized for achieving the Challenge, your company must join ENERGY STAR at thecompany must join ENERGY STAR at the corporate level.
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Food & Beverage Challengers*Food & Beverage Challengers
• 210 Sites from 23 from Food & Beverage Companies have• 210 Sites from 23 from Food & Beverage Companies have taken the Challenge.
• 30% of all Challenge sites are Food & Beverage sites30% of all Challenge sites are Food & Beverage sites
• 38% of all companies with sites in the Challenge are from the Food & Beverage sectore ood & e e age sec o
• 37 Sites fromFood Processors have achieved the Challenge– Avoided over 3,259,744 MMBTU & 18,000 MTCO2e– Ave savings = 14.3%
Whose taking the Challenge?• 148 - Dairy Sector (Mike, Cheese, Ice Cream)• 38 - Baking Sectors• 6 - Beverage (Juice, soda, etc.)• 18 - Snack, nut, cereal, etc. facilities
* As of April 2013 46
Engaging sitesEngaging sites
• Targeted energy awareness posters for industrial plantsp p
• Energy Treasure Hunt Guidance
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Energy Treasure HuntsEnergy Treasure Hunts
U i t l t ff t fi d i• Uses internal staff to find savings.
Focus on operational and low cost• Focus on operational and low-cost upgrade opportunities.
• Teach plant staff to find energy savings.
• Builds internal staff capability and ownership of implementation of projects.
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ConclusionConclusion
•Energy Strategy for the Road Ahead•Energy Strategy for the Road Ahead•Guidelines for Energy Management•Partnership letter
•EPIs plant benchmarks
Learn more at: energystar.gov
•EPIs, plant benchmarks•Challenge for Industry•Energy tracking system (M&V)• Energy Treasure Hunts
•Energy Guides•Teaming guide
•Challenge for Industry•Plant certification•Partner of the Year award
g g•Industry Focuses•SME guidance•iSPPs•Financial value calculator
•Case studies•Partner mentoring•Industry Focuses• Energy Treasure Hunts•EPIs, benchmarking Energy Treasure Hunts•Communication tools
, g(M&V)•Energy guides
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• Questions / Comments
