Ginsters cuts costs at Cornish bakery

12 November 2009

Ginsters is saving approximately 17 per cent a year on its chilled water energy bill at its Callington bakery in Cornwall, UK. The food manufacturer cut its costs after installing eight ABB standard drives for its chiller pumps.

The bakery, which employs 370 staff producing in excess of three and a half million pastry products a week, was keen to investigate its energy use to improve efficiency and cut costs at the plant.

Tom Crawford, projects manager, said: “Ginsters is committed to reducing its carbon footprint and this is part of our strategy to do so. Of course, it also makes good business sense to reduce the spend on utilities.”

Ginsters asked ABB to carry out an energy survey at the plant, which it did it with the help of ABB's Drives Alliance partner, APDS. The survey focused on the refrigeration system, in which chilled water pumps ran constantly with a full unrestricted flow. These pumps provide chilled water to the cold storage and production areas of the plant. Crawford said: “Although the application itself is not critical, it supports a system which is critical to the production facility.”

APDS measured the power consumption of the pumps over 24 hours and analysis showed that using a variable speed drive to achieve a speed reduction of only 6 per cent would reduce energy consumption, and therefore, operational costs by some 17 per cent.

A trial installation of an ABB drive showed improved stability of the system and again reduced power consumption. Following this, permanent ABB drives were installed on all pumps. Alan Jones of APDS said: “The drives have been running for eight months now and Ginsters are set to achieve a one year payback on the application.”

Crawford concluded: “Reduced power consumption has been realised on site and we know from the pre and post installation surveys that we are using less electricity to drive the pumps.”

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