They're Grrreat! Kellogg Reduces Energy By $3.3 Million Via the PI System

There are two food groups that everyone loves: breakfasts and snacks. The Kellogg Company happens to make both, which means their Battle Creek, Michigan plant may just be one of the happiest places on earth. From Frosted Flakes to Pop Tarts to the snap, crackle, and pop of Rice Krispies, Kellogg products are a staple in many of our morning routines.

In 2005, the company set ten-year energy targets and began using operational data from the OSIsoft PI System to achieve those goals, according to John Gothberg, Engineering & Facilities Manager at Kellogg, during his presentation at the 2016 OSIsoft User Conference.

The sustainable energy target project was built on the existing PI System infrastructure that was put in place in 1999-2000. “When we set the 10-year energy targets, PI was the natural go-to for us,” said Gothberg. “We had a lot of success with the OAE project in measuring real-time data to feed decisions on the floor.”

In addition, Project Montage preemptively installed gas, air, and primary voltage metering as well as hundreds of PI System tags, which would allow the team to benchmark the upcoming energy targets and measure progress and successes.

To achieve these great results, it's an ongoing endeavor, so the Kellogg team developed the seven step Sustainable Process

  • 1.Develop Partnerships: Engage everyone from the people on the plant floor to business partners in finance and operations as well as those who understand your process
  • 2.Gather Data: Be creative and measure things close to the source - and find a smart team of people for analysis
  • 3.Identify the Opportunities: Look for quick wins, rally the right team, and don't forget to challenge everything
  • 4.Measure the Opportunities: Collect the right historical data and analyze accordingly
  • 5.Execute the Project: Have the right data to unlock capital and use that opportunity to be strategic and fuel the next project
  • 6.Validate the results: Get as much as possible out of the PI System, communicate findings and leverage information to find additional savings
  • 7.Repeat!

This process is what ultimately led to Kellogg's ability to gain visibility into its six HVAC units inside the plant that were all controlled by a building management system. With data from the OSISoft PI System they realized that, to keep the coils from freezing, they were heating up air only to cool it down again. Some of that air that was being brought in from the outside, and it was not linked to the building management system, which presented food safety risks and nearly nullified building pressure. They were able to remedy the situation with retrofitting, which saved a substantial amount of money and got the company closer to their energy consumption goals.

 

 

Not only that, data showed an additional opportunity to save money on energy costs with the pumps that had been installed to push recycled water through the coils to keep them from freezing. Fresh air was being brought into one HVAC unit at a time, but Kellogg discovered that if this was done for all six units simultaneously, they could mix in the return air from the building and bring in enough makeup air to not need water heating at all. In just one week in February, they saved over $40,000 dollars with this simple change.

“We selected the PI System in 2000,” said Gothberg. “And, in those years, our plant is now saving $3.3 million dollars annually and has claimed $1.3 million dollars in rebates - and those rebates unlocks don't come without data.”

Overall, the project has been a great success, and that's because the Kellogg Company laid the right project and data infrastructure groundwork. To learn more about how Kellogg used the OSIsoft PI System to meet their energy targets and identify additional opportunities, read the whole story here.