Energy Efficiency Improvement and Cost Saving Opportunities for the Fruit and Vegetable Processing Industry
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LBNL-59289-Revision ERNEST ORLANDO LAWRENCE BERKELEY NATIONAL LABORATORY Energy Efficiency Improvement and Cost Saving Opportunities for the Fruit and Vegetable Processing Industry An ENERGY STAR® Guide for Energy and Plant Managers Eric Masanet, Ernst Worrell, Wina Graus, and Christina Galitsky Environmental Energy Technologies Division Sponsored by the U.S. Environmental Protection Agency March 2008 Disclaimer This document was prepared as an account of work sponsored by the United States Government. While this document is believed to contain correct information, neither the United States Government nor any agency thereof, nor The Regents of the University of California, nor any of their employees, makes any warranty, express or implied, or assumes any legal responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by its trade name, trademark, manufacturer, or otherwise, does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof, or The Regents of the University of California. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof, or The Regents of the University of California. Ernest Orlando Lawrence Berkeley National Laboratory is an equal opportunity employer. LBNL-59289-Revision Energy Efficiency Improvement and Cost Saving Opportunities for the Fruit and Vegetable Processing Industry An ENERGY STAR® Guide for Energy and Plant Managers Eric Masanet, Ernst Worrell, Wina Graus, and Christina Galitsky Energy Analysis Department Environmental Energy Technologies Division Ernest Orlando Lawrence Berkeley National Laboratory University of California Berkeley, CA 94720 March 2008 This work was funded by U.S. Environmental Protection Agency’s Climate Protection Partnerships Division as part of ENERGY STAR. ENERGY STAR is a government-backed program that helps businesses protect the environment through superior energy efficiency. The work was supported by the U.S. Environmental Protection Agency through the U.S. Department of Energy Contract No. DE- AC02-05CH11231. Energy Efficiency Improvement and Cost Saving Opportunities for the Fruit and Vegetable Processing Industry An ENERGY STAR® Guide for Energy and Plant Managers Eric Masanet, Ernst Worrell, Wina Graus, and Christina Galitsky Energy Analysis Department Environmental Energy Technologies Division Ernest Orlando Lawrence Berkeley National Laboratory March 2008 ABSTRACT The U.S. fruit and vegetable processing industry—defined in this Energy Guide as facilities engaged in the canning, freezing, and drying or dehydrating of fruits and vegetables—consumes over $800 million worth of purchased fuels and electricity per year. Energy efficiency improvement is an important way to reduce these costs and to increase predictable earnings, especially in times of high energy price volatility. There are a variety of opportunities available at individual plants in the U.S. fruit and vegetable processing industry to reduce energy consumption in a cost-effective manner. This Energy Guide discusses energy efficiency practices and energy-efficient technologies that can be implemented at the component, process, facility, and organizational levels. A discussion of the trends, structure, and energy consumption characteristics of the U.S. fruit and vegetable processing industry is provided along with a description of the major process technologies used within the industry. Next, a wide variety of energy efficiency measures applicable to fruit and vegetable processing plants are described. Many measure descriptions include expected savings in energy and energy-related costs, based on case study data from real-world applications in fruit and vegetable processing facilities and related industries worldwide. Typical measure payback periods and references to further information in the technical literature are also provided, when available. Given the importance of water in fruit and vegetable processing, a summary of basic, proven measures for improving plant-level water efficiency are also provided. The information in this Energy Guide is intended to help energy and plant managers in the U.S. fruit and vegetable processing industry reduce energy and water consumption in a cost-effective manner while maintaining the quality of products manufactured. Further research on the economics of all measures—as well as on their applicability to different production practices—is needed to assess their cost effectiveness at individual plants. iii iv Table of Contents 1 Introduction....................................................................................................................... 1 2 The U.S. Fruit and Vegetable Processing Industry........................................................... 4 2.1 Economic Trends...................................................................................................... 5 2.2 Sub-Sector Overviews.............................................................................................. 6 2.3 Fruit and Vegetable Processing Trends .................................................................... 9 2.4 Imports and Exports................................................................................................ 11 2.5 Industry Structure and Characteristics.................................................................... 12 3 Overview of Fruit and Vegetable Processing Methods .................................................. 14 3.1 Unit Processes......................................................................................................... 14 3.2 Process Flow Diagrams........................................................................................... 21 4 Energy Use in the U.S. Fruit and Vegetable Processing Industry .................................. 28 4.1 Energy Expenditures............................................................................................... 28 4.2 Energy Consumption and End Uses ....................................................................... 31 4.3 Process Energy Intensities ...................................................................................... 35 5 Energy Efficiency Improvement Opportunities.............................................................. 40 6 Energy Management Programs and Systems.................................................................. 45 6.1 A Strategic Energy Management Program ............................................................. 45 6.2 Energy Teams ......................................................................................................... 47 6.3 Energy Monitoring Systems ................................................................................... 48 7 Steam Systems ................................................................................................................ 50 7.1 Boiler Energy Efficiency Measures........................................................................ 50 7.2 Steam Distribution System Energy Efficiency Measures....................................... 55 7.3 Process Integration.................................................................................................. 56 8 Motor Systems and Pump Systems................................................................................. 59 8.1 Energy Efficiency Measures for Motor Systems.................................................... 59 8.2 Energy Efficiency Measures for Pump Systems..................................................... 64 9 Refrigeration Systems..................................................................................................... 69 9.1 Refrigeration System Management......................................................................... 70 9.2 Cooling Load Reduction......................................................................................... 72 9.3 Compressors............................................................................................................ 74 9.4 Condensers and Evaporators................................................................................... 76 10 Compressed Air Systems ............................................................................................ 79 10.1 Energy Efficiency Measures for Compressed Air Systems.................................... 79 11 Building Energy Efficiency Measures........................................................................ 88 11.1 Energy Efficiency Measures for HVAC Systems................................................... 88 11.2 Energy Efficiency Measures for Lighting............................................................... 93 12 Self Generation........................................................................................................... 97 13 Process-Specific Energy Efficiency Measures ......................................................... 101 13.1 Energy Efficiency Measures for Blanching.......................................................... 101 13.2 Energy Efficiency Measures for Drying and Dehydrating ................................... 102 13.3 Energy Efficiency Measures for Evaporation....................................................... 105 13.4 Energy Efficiency Measures for