Kerry Foods achieves cost and carbon reductions with MRO programme

By implementing a programme from Brammer, a distributor of maintenance, repair and overhaul (MRO) products and services, Kerry Foods has achieved immediate cost savings and reduced its carbon emissions.

Kerry Foods specialises in food ingredients and flavours, and supplies branded foods to the Irish and UK markets. Aiming to reduce energy consumption, the engineering services group leader at its Spalding plant invited Brammer to investigate various systems around the factory to identify areas for improvement.

Andy Hickin, regional key account executive for Brammer, explains, “Our audit of the Kerry Foods facility soon established that motors powering three separate systems were constantly running at full capacity, with no means of controlling speed to match demand. After demonstrating the possible carbon savings – as well as the short payback period – achievable by providing variable speed control to these motors, an upgrade project was agreed with the customer.”

The motors involved in the project included a 7.5kw motor used to maintain higher air pressure within the plant than outside; an 18.5kw motor powering high-pressure hot water for equipment wash-downs; and a 15kw motor delivering water for hand washing at a lower pressure. With the water motors running 24 hours a day and the air pressure running at full speed 13.5 hours per day, all across five days a week, the motors had a combined running cost of more than £18,000 per year.

Brammer’s recommendation of fitting Siemens variable speed drives to each system has resulted in an annual cost saving of more than £9,000, coupled with a carbon emissions reduction of 67 tonnes per year. The drives used allow the control of motor speed to match the flow demand within the factory, and payback for two of the motors was achieved within less than six months.

Stuart Burgess, engineering services group leader at Kerry Foods in Spalding, comments, “Reducing carbon emissions is key to the food and beverage industry at present, with manufacturers tasked with achieving a significant reduction in consumption by 2020. With the help of Brammer and the newly-installed variable speed drives, we have made a big step towards hitting our targets and optimising the efficiency of our production processes.”

A partnership with Siemens was vital in achieving cost savings for Kerry Foods. Hickin continues, “Brammer and Siemens have a shared objective to reduce energy consumption in the workplace, which also leads to cost savings for customers. Together, the two companies have developed a training programme for Brammer personnel, giving us the knowledge of Siemens products to recommend the most effective solution for a wide variety of situations faced by customers.”

The programme provides Brammer workers with awareness and knowledge of Drive Train related products, system efficiency, savings potential and sales opportunities, helping customers to comply with energy related legislation and to reduce energy costs and emissions.

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