Working with a food processing plant here in Missouri served by Ameren and their energy intensity ratio is way above DOE manufacturing benchmarks. They're running 28 kWh per pound of product versus the industry benchmark of 18 kWh/lb for similar facilities. Plant manager insists operations are normal but the numbers don't lie. Anyone dealt with food processing benchmarks where refrigeration loads dominate? Starting to wonder if the DOE data excludes cold storage and blast freezing operations.
Manufacturing energy intensity ratios - when benchmarks don't match reality
Elmer, food processing benchmarks are notoriously unreliable because of the huge variation in processes. Here in Memphis, I've worked with several meat processing facilities and their refrigeration loads can be 60-70% of total usage. The DOE studies often lump different food categories together and don't account for cold chain requirements. What type of products are they processing? Fresh, frozen, or both?
Amir's right about refrigeration loads being the wild card. I had a similar case with a poultry plant here in Alabama served by Alabama Power. Their energy intensity was through the roof until we realized they were running redundant refrigeration systems due to food safety requirements. Sometimes "inefficiency" is actually regulatory compliance. Elmer, check their HACCP requirements - might explain the higher energy use.