Smithfield Foods Corporate Engineering Energy Reduction Technical Guidance August 5, 2011

1. Smithfield Foods Corporate Engineering Energy Reduction Technical Guidance August 5, 2011 Paul Kafer

2. Energy Reduction Strategies LIGHTING: • Replace Metal Halide fixtures with T8/T5 Fluorescent or LED. • For new installations, use T8/T5 or LED. • Consider solar powered LED for outside areas (i.e. parking lots). • Use motion detectors. • Example: 2 offices in Smithfield converted from T12 to T8. After one year, electricity usage dropped by approximately 25%. • Contact Lee Casey at 757-356-6712 for help or a plant audit.

3. Energy Reduction Strategies

4. Energy Reduction Strategies

5. Energy Reduction Strategies

6. Energy Reduction Strategies AMMONIA REFRIGERATION: • Intelligent Refrigeration Controls- these will monitor various system parameters and automatically adjust pressures and compressor operation. Sioux Falls has a system in place. • Lower set point for discharge pressure- typically these are set at 150 psi, but most systems can run at 120 psi in cooler weather. • Consider using a heat exchanger to create hot water- this technology uses a high pressure compressor and plate and frame heat exchanger to create hot water (140 degrees F). • Contact Ken Kmak at 850-673-9962 for help or for a plant audit.

7. Energy Reduction Strategies MOTORS: • Perform motor audit: especially for plants with large number of conveyors. Look for instances where a motor has been installed with a higher HP than is needed for the application. • Replace older, larger motors with NEMA Premium motors. • Install Variable Frequency Drives (VFDs) on larger motors (blenders, grinders, condenser fan motors, air compressors, etc). • Install soft starts on large motors where VFDs are not needed. • Contact Lee Casey for help. Another source is to use our motor suppliers.

8. Energy Reduction Strategies COMPRESSED AIR: • Rule of thumb: it costs $.01 to generate one cfm/hr of air. • Perform leak audit- this involves installing flow meters in lines and recording data over one to two weeks. • Evaluate piping for pressure drops. • For larger systems, have one air compressor to handle base load and another compressor(s) operating on VFDs for swings in load. • Keep air dry. Some systems have been developed to recover waste heat from compressor to regenerate dessicant on air drier.

9. Energy Reduction Strategies BOILERS: • O2 trim controls. • Economizers and blow down heat recovery. • Convert from using steam for hot water to using direct fired gas heater. • Recover condensate. • Steam trap surveys. • Lower steam pressure is possible.

10. Energy Reduction Strategies OTHER NATURAL GAS SUGGESTIONS: • Perform stack analysis on major combustion systems (ovens, etc) and tune burners for proper fuel to air ratio. • Inspect main gas lines and regulators for fugitive leaks. • Install meters on major consumers of natural gas.

11. Energy Reduction Strategies CONDENSATION AND ENERGY: • Most condensation issues are caused by poor airflow- too much exhaust and not enough make up air. • Plants resort to installing or renting dehumidifiers (Munters, Bry-Air). • These units consume large amounts of energy (usually natural gas) to regenerate a desiccant wheel. • A more practical, less costly and less energy intensive approach is to correct the poor air flow in the plant. • Contact Ken Kmak for help.