| Energy Optimization - Case |
| Carlsberg is Brewing Energy Savings |
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With 3Tech Automation as its business partner, the brewery in Fredericia is focusing on the optimization of all areas of its energy consumption.. - The production of each single beer should be as cheap as possible. Carlsberg Denmark A/S aims to become a green company and Karsten Østergaard, the Supply Manager of the brewery, makes a great effort to lower the energy consumption of the brewery in Fredericia. His energy budget comes to almost 100 mill. DKK. – a heavy and growing expenditure which would have amounted to the same level as the greatest expenditure of the brewery - the payment of wages to its employees, if no steps had been taken to lower the energy consumption. With 3Tech Automation as an external business partner when it comes to data collection, visualization, and program optimization of the energy centre, Karsten Østergaard is aiming at reducing the expenditure for energy which is consisting of the consumption of electricity, water, heating, ventilation and waste water. - We are increasingly focusing on energy to utilize it in the cheapest possible way by the optimization of all aspects of energy, the Supply Manager says continuing: - We are continuously optimizing each and every process through the fine-tuning and valuation of the processes seen in the light of saving energy. We compare the production data with the energy consumption to identify how production affects the consumption of energy – measured by the hectoliter beer. And because we expect to find up to 30 pct. of our future savings here, we focus on the behavior of our employees. In general, the employees are the key to succeeding with the energy saving effort. Data collection and visualization Seen from the point of view of the employees, it is difficult to see when/if they make a difference. This is the reason why data collection and visualization has been the key points of the work of 3Tech Automation with creating measuring systems to make it easy for the employees to overview and change the consumption of energy. - Already, we had approximately 200 measuring points and now we have up to 1,000 more points to collect data from – e.g. measured by the energy consumption of a certain machine. An interface to the existing and the new data has been established and several systems have been coordinated into a common reporting system, Karsten Østergaard states who makes a weekly reporting of the energy consumption to the management team of Carlsberg. With the new measuring system they now have a new tool that is easy to work with and provides a swift visualization to the employees of the consumption of energy. |
Easy to operate By the Microsoft SQL and Rockwell’s Factory Talk VantagePoint systems, data from approx. 1,200 measuring points are extracted, each with their own ID-number. Microsoft Excel , which is familiar to most people, is applied for the layout of the reports before these are published in the Factory TalkVantagePoint to be shown by a general internet browser. The data collection itself is carried out by FactoryTalk Transaction Manager collecting data from Rockwell PLCs and from the measuring modules of the Ethernet by the Modbus OPC. The data is saved in a Microsoft SQL database. Data are also collected from another system called Desigo, which includes data from the local soft drink production. - I make all the reporting myself in Excel. It is easy to work with and provides quickly the data I need. The way it is set up, I need no contact to 3Tech Automation each time I have to prepare a report. Everyone with a password has access via the intranet to seeing the reports and the consumption of energy within the latest 24 hours on their PC. No other software is required, Karsten Østergaard explains adding that the consumption is translated into Danish currency to the employees. - It is easier to relate to than kilowatt for example, he says. Follow-up of LEAN-boards At the moment, the reporting to the employees is typically made by department, however according to the Supply Manager, within a year, the reporting will be separated into columns (the brewery has 11 columns). In the long term we are planning to make a follow-up of the LEAN-boards. - The target is that each employee will be able to view on a screen the consumption of electricity and water of each single operation – and to act immediately if the consumption is too large, Karsten Østergaard points out who is aiming at increasing the competency of the employees in the field of energy. - Our target is to make them ”do as they do at home” when it comes to energy saving. The tool to depict the effect of their attitude in the field of energy is now available. An important tool to visualize to them the importance of energy saving and how much they can “move” the consumption, he says. All in a single system Karsten Østergaard describes 3Tech Automation as ”good or almost outstanding at joining it all in a single system”. Add to this the advantage of the distance of less than a kilometer between Carlsberg Brewery and 3Tech Automation. |
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