Food Processing

Rising energy costs have a detrimental effect on the bottom line for food processors leading them to look for ways to cut costs through a reduction in their energy consumption. A growing trend in the industry is package redesign to lower energy bills and reduce the environmental impact of packaging. Increasing energy efficiency in processing facilities is the most effective way to lower processing costs, increase the bottom line and reduce greenhouse gas emissions.

According to an EPA study, processing accounts for about 78% of the energy used by food processors. Of that, 54% is used for process heating, 30% for motor-driven equipment and 1% for refrigeration and cooling. Increasing the energy efficiency of the equipment and employing alternative fuel sources can considerably lower your energy bills. Saving $1 in energy cost equates to a top line revenue of over $8.

Star Energy is experienced in helping food processors effectively reduce their energy use. A customized energy cost reduction program enables us to identify improvements at your facility, equipment and process levels and implement financially feasible measures to significantly decrease your energy costs. Our exclusive ECRp® program systematically identifies energy cost reduction opportunities that fit your financial criteria, typically delivering an IRR of over 30%. Our process begins with an analysis of at least one year's worth of utility bills, followed by a thorough inspection of the building envelope and the systems used in processing, including HVAC, refrigeration, lighting, motor-driven equipment and distribution systems for compressed air, steam and hot water. Using this information, we develop a comprehensive list of practical, sustainable, and cost-effective improvements that will reduce the annual utility.

Improvements may include employing new technologies, using alternative fuel sources and utilizing waste recovery. Combined heat and power alone, can result in 80% efficiency, compared to 33% efficiency with delivered electricity. A comprehensive monitoring and tracking plan would help you maintain lower energy consumption for the long-term.

In addition to equipment upgrades, retrofits and replacement no cost and low-cost improvements can have a serious impact on you bottom line. For example, replacing existing lighting with high output fluorescent lamps can result in a 50% reduction in the energy used for lighting, while variable speed drives on electric motor-driven equipment can reduce energy consumption by 20 to 50%.