Case Study
Maximizing Efficiency: Chobani’s Success Story with Ever.Ag’s Energy ManagerAt a Glance
| Customer: | Chobani |
| Industry: | Dairy |
Chobani is the largest yogurt manufacturer in the US. The company is growing rapidly, expanding its presence across food & beverage categories while building out a global manufacturing footprint. Chobani installed Ever.Ag’s Energy Manager platform at all their US and Australian locations, including the world’s largest yogurt facility at Chobani’s Idaho location.
Challenges
Chobani required a solution that would enable them to identify, monitor and target the largest energy consumers at their facilities. They looked to engage in energy reduction projects to reduce their overall consumption and carbon emissions. This solution needed to be scalable and available to deploy across the organization. Given the scale of the organization and the breadth of equipment requiring monitoring, the management team sought a solution that could rapidly deliver actionable energy insights without the cost and disruption of deploying extensive physical metering infrastructure.
Challenges
Chobani required a solution that would enable them to identify, monitor and target the largest energy consumers at their facilities. They looked to engage in energy reduction projects to reduce their overall consumption and carbon emissions. This solution needed to be scalable and available to deploy across the organization. Given the scale of the organization and the breadth of equipment requiring monitoring, the management team sought a solution that could rapidly deliver actionable energy insights without the cost and disruption of deploying extensive physical metering infrastructure.
Chobani had corporate requirements to achieve the following:
Identify significant energy users
and energy flow at the facilities.
Track equipment performance,
processing and energy usage.
Continuously monitor, review and track
energy and savings opportunities.
Integrate data
for energy and performance to SAP.
With the unique Energy Manager technology, Chobani could:
Compile complete energy maps
for all WAGES from a building level to the process equipment.
Model the production process,
map equipment performance characteristics and build cycle time reports with batch energy data.
Grow the system modularly,
allowing for the targeted analysis and review of specific energy users.
Integrate data to SAP
for managerial dashboards and site reportin.
Ever.Ag Solutions
Chobani selected Ever.Ag’s Energy Manager solution to maximize efficiency while minimizing capital investment and implementation complexity. The solution provides the necessary information and analytical tools to enable Chobani to implement their energy reduction and plant performance program quickly and efficiently. The Energy Manager platform was deployed and integrated with their Historian to collect data from disparate data sources such as the Process Control System, BMS, and standalone OEM units.
Ever.Ag Solutions
Chobani selected Ever.Ag’s Energy Manager solution to maximize efficiency while minimizing capital investment and implementation complexity. The solution provides the necessary information and analytical tools to enable Chobani to implement their energy reduction and plant performance program quickly and efficiently. The Energy Manager platform was deployed and integrated with their Historian to collect data from disparate data sources such as the Process Control System, BMS, and standalone OEM units.
By leveraging the Historian for Energy Manager’s virtual metering on equipment and process
energy flow, the facility gained an understanding of their usage and profile over a few weeks. The Energy Manager platform quickly identified users, processes and operational activities that could be changed quickly and efficiently to kick off the reduction and performance improvement program.
Projects
Using the information provided by the Energy Manager platform, Chobani could confidently propose several energy and process improvement projects ranging from significant scale capital expenditure to low- / no cost system and work practice changes
Some of the implemented projects are:
Chiller Optimization
Estimated saving over $300K/year
Process Improvement
Estimated saving over $200K/year
Water Optimization
Saving over 250K gal/day
Results
The results achieved by Chobani clearly show the benefits of using the Energy Manager platform instead of a traditional metering solution.
A reduction of over 60% in capital expenditure by using Energy Manager compared to
alternative systems.
Zero plant downtime for installing and configuring the Energy Manager platform.
Identify energy users and projects within weeks of the Energy Manager deployment.
The Energy Manager identified inefficient processes, operational activities and equipment using excessive energy and underperforming in cycle time analysis investigations.
Looking Ahead
The Energy Manager platform provides Chobani with a targeted analysis toolset that is easily expanded upon. Weekly energy usage reports and baseline information enable management to keep an active view of the facility reviewing during regular facility business meetings.
Chobani will continue utilizing and expanding the Energy Manager platform at their facilities to achieve its energy reduction targets. Continued expansion of the solution across the facilities will allow for the complete aggregated analysis of the organization. The Energy Manager platform has provided a greater understanding of energy usage and its associated costs.
Chobani continues to strive and will now target to achieve ISO 50001 certification for energy management. The Energy Manager platform powers the monitoring and analysis required to achieve this goal.