Case 1: StyleMark
World’s Largest Sunglasses Maker Saves Over 50% with Eniscope
StyleMark is the world’s largest sunglasses manufacturer. In 2006 they shipped a phenomenal 35 million units and currently, 1 out of every 3 pairs of sunglasses sold in the United States are made by StyleMark*.
As with many other large manufacturers, energy is becoming an increasingly significant component of their operating budget. In an effort to bring their spiralling energy costs under control they turned to Eniscope – A Real-time Energy Management System.
A trial was set up on a key distribution panel in their main factory. Eniscope immediately picked up on an HVAC problem that had previously gone unnoticed. A simple strategy was recommended in response to the information revealed by Eniscope and within two weeks the energy consumption on that panel had been reduced by over 50%. This equated to a saving of over $10,000.
StyleMark subsequently fitted Eniscope to all of their main distribution panels and are now on course to achieve facility-wide savings of 20% in the first 12 months.
*In their channel of trade
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Case 2: KFC, South Africa
Moral Food’s owner, Mr. Rughubeer contacted Scott Fuller, EnergyRite’s Managing Director, after hearing about the savings the company had achieved for another local business.
Facing increasing energy costs across his estate of 16 successful stores in the KwaZulu Natal region, Mr. Rughubeer was keen to get a better understanding of the energy hotspots within his business and identify opportunities for savings.
EnergyRite performed a full site audit and set about installing BEST’s state of the art, real-time energy monitoring solution, Eniscope, within the Inanda and Phoenix stores that would act as a pilot for a wider store roll out.
The data collected through Eniscope allowed Scott and his team to perform a detailed analysis of the energy consumption within those stores, allowing for no or low-cost savings to be identified and presented to Mr. Rughubeer.
“Using data collected in real-time from BEST’s sophisticated analytical software I was amazed how quickly potential areas of savings were identified. Within the first month, we were saving Mr Rughubeer a substantial amount of money.” Says Scott Fuller.
Key to those energy reductions was a process called ‘Daily Start-Up Synchronisation’ where Scott and the EnergyRite team identified patterns in the daily routines and processes at the stores. Using these patterns as a baseline they were able to identify opportunities for reduction and monitor the effects in real-time.
At an equipment level, on-site chillers were fitted with timers and thermostats, eliminating the wasteful legacy system that relied on pressure pads. LED lighting was fitted throughout each store, front and back, including signage.
￼Over six months Energyrite were able to generate a total of R148,190 (around £8,500) of savings across the two stores’ electric bills, cutting nearly a quarter (24%) of their total monthly electrical consumption. In simple terms, this could be equated to the cost of providing 5,951 Streetwise 2 meals to customers.
However, the energy savings don’t stop there, Scott and the team at EnergyRite have been given the green light to extend the pilot to the remaining 13 stores and are already in the process of identifying further reductions across those stores.
The success has opened up doors with other franchisees across the region, with negotiations for a further 150 stores already underway, and the potential to install across the 900 KFC franchises within South Africa in the future.
Moral Foods owner, Mr. Rughubeer says, “We are delighted with the results EnergyRite have been able to achieve, they have exceeded our expectations.”
- Benefits: On-site chillers were fitted with timers and thermostats, eliminating the wasteful legacy system.
- Savings: In simple terms, this could be equated to the cost of providing 5,951 Streetwise 2 meals to customers.
Case 3: Dunedin Dominos, Florida
The Dunedin Dominos store, in the state of Florida, is one of three franchises owned and operated by local businessman Mike McDermott.
His store was recently selected to act as one of six test pilots for energy saving by the Dominos Franchisee Association (DFA) which represents the 2,500 independent business owners who operate close to 60% of Dominos’ US locations.
Florida based BEST distributor, Eco Energy, were engaged to work with six independent stores across the US, representing the geographic and climatic variety of the wider group. Should Eco be able to demonstrate savings exceeding 20% across the test sites, a national roll-out would begin.
A Systematic Approach
Following the systematic EnergyMaps process, Eco Energy installed Eniscope Real-Time Energy Monitoring at the Dunedin store in order to gauge a baseline. This would enable the Eco team to pinpoint savings and demonstrate the effectiveness of any remedial action taken.
“The benefit of the EnergyMaps process is that it allows you to see where you were before and what your potential energy reductions can be.” Says Mike.
Targets for Reduction
Immediately after installing the Eniscope equipment a load imbalance was identified at the store; however, a period of monitoring was required to verify that this was an on-going issue and not just a temporary fault.
By comparing store opening times with energy consumption patterns at the store further targets for reduction were identified.
By reviewing the full Eniscope data gathered over a period of 4 weeks it was possible to determine the main areas of energy consumption at the store and provide a detailed plan of action to reduce consumption.
The plan identified a range of no or low-cost options, as well as a number of targets for load reduction through retrofit, energy saving devices.
Mike agreed to the proposed plans and work began to start reducing the store’s energy consumption.
AircoSense, a retrofit device capable of reducing the energy consumption of air conditioning systems by up to 35%, was installed on the air con.
A Chilled Unit Energy Saver (CUES), a retrofit device that can reduce the energy consumption of refrigeration by up to 33%, was installed on the stores walk-in freezer.
An Intelligent Motor Energy Controller (iMEC) was installed on Dunedin’s refrigerated ‘make table’, ensuring that the torque was set to match it’s load, with potential savings of up to 10%.
LED lighting and occupancy sensors were installed throughout the store, with the potential for savings of 50% upwards.
An Impressive Result
All the improvements to the store were delivered on a 2.4-year payback against KWh savings alone, factoring in maintenance reductions a further 30% could be knocked off this period, bringing the ROI inside 2 years.
The store immediately benefitted from an energy reduction, and by monitoring energy consumption for a period of months following the changes, it has been possible to track the savings made. Those savings total 34% of the stores on-going energy consumption, a significant reduction in the energy bill, and well above the 20% target.
A similar result has been achieved across the other five stores in the pilot. The DFA has reviewed the results and a national rollout is expected to begin later this year.