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Poultry Savings for 2 Sisters

Excalibur undertook the installation of Liquid Pressure Amplification and installed a Variable Speed Drive system to control the unit's condenser fans.

Like most organisations, 2 Sisters Food Group is coming under increasing pressure to reduce its environmental impact and control costs.

With this in mind, engineering staff at the chicken products supplier's Haughley Park facility invited Excaliburto conduct an energy efficiencysurvey of the site's existing refrigeratio systems.

Based on this survey and results from an internet-based refrigeration efficiency monitoring system, Excalibur made a number of recommendations and was contracted to carry out modifications to the site's equipment.

Initially the plant's Roast 95 pack was selected formodification: This installation features four Bitzer OSK 7471 screw compressors and an aircooled seven-fan condenser. The system is used to chill cooked chicken and operates seven days a week.

Excalibur undertook the installation of Liquid Pressure Amplification and installed a Variable Speed Drive system to control the unit's condenser fans. The work was undertaken with no disruption to production, prefabrication being completed during normal working hours and final connections made during a weekend shutdown.

The internet-based refrigeration monitoring system used in the initial survey was left in place and this also allows online access to all refrigeration operating parameters.

Following 12 months of monitoring, the engineering staff at Haughley Park are now in a position to assess the improvement in refrigeration efficiency as a result of Excalibur's modifications to the system.

Since the improvements were implemented, energy consumption has been reduced by 38 per cent, giving a return on investment of less than 15 monthsand an annual reduction in carbon emissions of 177 tonnes.

The introduction of low head pressure operation and inverter control of condenser fans has also reduced the mechanical stress on compressors and fans, which will reduce the risk of potential failures.

Even the Chancellor is doing his bit, as the entire project qualifies for Enhanced Capital Tax Allowances!

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Andy Watson | Energy Manager | BAA Heathrow Airport

"Following successful trials Excalibur have undertaken the installation of Liquid Pressure Amplification, inverter control of condenser fans and adiabatic condenser cooling to all of the large packaged chillers at Heathrow Airport, this project was completed successfully despite the difficulties of working airside.

As a result of the improvements in chiller efficiency, Excalibur have successfully completed similar projects at Stansted, Edinburgh and Glasgow Airports. "

Chris Prentice | Project Management | UK NRG LTD

"Excalibur have installed Liquid Pressure Amplification and Inverters to 2 off 1300 kw data centre, process chillers. The cooling system is critical to this business, Excaliburs’ professional approach provided the customer with the confidence to undertake the project. Their condition monitoring also raised several maintenance issues, which we were able to resolve during the contract. Initial monitoring is demonstrating a 46% reduction in electrical consumption."

Tony Bacchetta | Guoman Hotels

Excalibur have completed energy efficiency projects in many of our hotels, one of our major concerns is any disruption to the operation of the hotel and our customers.

The work was completed to a very high standard, and we were always kept informed of progress.

We are achieving the level of energy reduction projected with no adverse affect on the business and would have no hesitation in using Excalibur again.

George Fletcher | Senior Project Manager | Norland Managed Services

I would like to take this opportunity to thank you and all others from within Excalibur involved with the development of this project, from my initial involvement through to today's handover meeting. All of which has run extremely well, with any issues uncovered being easily resolved with the proactive nature of you and your site team, which are a credit to Excalibur.

Hopefully, in the not to distant future I will have the opportunity to call upon Excalibur’s assistance and experience again on another LPA Project. Though in between times I would thank you again for your support and guidance.

Services Facilities Manager | Manchester Airport

"Throughout the LPA project at Manchester Airport Excalibur provided a thorough and professional service ensuring the project was delivered on time with minimal operational disruption. The project delivered savings as quoted, the refrigerant change helped re-life ageing equipment and was seen as a great success, so much so that we are about to embark upon a second phase during 2010"

Darren Crook | Operations Director | J O Sims Ltd

“Not only were the improvements in efficiency immediate and measurable, but previously it could take 48 hours to pull a chamber down to temperature, this can now be achieved in 12 hours, enabling us to respond to customer requirements very much quicker”.

2 Sisters Food Group

"Excalibur installed LPA and inverter control to our Bitzer screw pack, the work was completed to a very high standard with minimum effect to production. Monitoring over the first 12 month period showed a reduction in power consumption of 38%. Several evaporators which had been starved of refrigerant now achieve temperatures where previously they struggled.
There have been no reliability issues and we are benefiting from a system which is not only energy efficient but also provides  improved refrigeration performance"

Dave Jeffs | Energy Matters

I have employed Excalibur to improve the energy efficiency of 8 Dunham Bush and Hitachi process chillers on two newspaper print sites, both systems showed a reduction in power consumption in excess of 35%. The installations were undertaken 6 years ago and have operated reliably since their commissioning. I would have no hesitation in working with Excalibur again.

 

Richard Shoulders | Operations Project Manager | British Telecom

"Excalibur have been undertaking energy efficiency projects for British Telecom for over 10 years, as a company they have always been professional and diligent. Their proactive approach has also identified several areas where we have been able to improve the integrity of our equipment."

Andrew Miller | General Manager | Euro Foods Ltd

Before installation Excalibur monitored all three refrigeration systems to establish their condition

The work was carefully planned and shut-down periods were kept to a minimum.

Following the modifications, the system now operates more efficiently at much lower head pressure.

Technical Manager | Avalon Leisure

"Excalibur completed energy efficiency projects at 3 of our Leisure Centres, the installation of boiler and inverter control (to pumps and fans) showed a very impressive reduction in both gas and electricity consumption on all 3 sites.

The opportunities were identified by Excalibur, who then completed the work to a very high standard, and have continued to provide support as required."

 
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