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Case study

Freybe Gourmet Foods

Freybe Gourmet Foods

Total GHG Inventory

  • 2009: 4,771 tonnes CO2e
  • 2011: 4,399 tonnes CO2e

GHG Reduction Highlights

  • Savings on electricity, natural gas, water, and fleet fuel

Projected Reductions

  • 20% off electricity
  • 15% off natural gas
  • 3,500 cubic meters of water

Freybe Gourmet Foods, Ltd. is a 6th generation family run business, manufacturing deli meats, sausages, hams and other specialties according to European traditions. Freybe is working to reduce its annual CO2e emissions through improved natural gas heating and cooking systems in order to sustain the future for generations to come.

By starting with low cost (or no cost) solutions, Freybe has been quickly realizing emissions and cost savings—some with immediate paybacks. They are building the case that there is money to be made in pursuing emissions reductions and continuing on to more capital-intensive projects, both now and in the future.

Freybe began by analyzing the operating hours of their manufacturing facility in Langley. Redistributing shifts and compressing their workweek by 6 hours immediately reduced their overall energy consumption by 2% and it cost them nothing.

Freybe has also saved over 530,000 kWh of electricity in the last 9 months. By switching their lights from metal-halides to T5s, they now save nearly 400,000 kWh annually with a capital investment of $39,000 plus labor. They have installed variable frequency drives (VFDs) on all of their refrigeration units. This allows them to adjust output and energy consumption based on demand. With further investment in automated control, they expect to increase their savings to nearly 1,000,000 kWh annually: cutting over 12% off their total annual electricity usage. They have further set a reduction goal of 20% (electricity) by the end of October 2011.

Freybe is also working to reduce their natural gas use. In reexamining their high-pressure boiler setup, staff determined that the risk of boiler failure was low. They decided that they didn’t need to keep a backup boiler on constantly. By shifting to a “dry-layup” procedure where the backup is only fired when needed, they can practically eliminate its use. In addition, they have found a way to step down excess high-pressure steam to provide low-pressure steam for other processes, eliminating the need for their low-pressure boiler. Changing how they use their equipment has effectively reduced their requirement for three boilers down to one. The actual annual savings will not be determined until they have tracked the current year’s natural gas usage and compared it with that of last year; however, over 15% savings are expected, equating to a 5-month payback.

They are now regularly checking their steam traps and compressed-air-system to ensure maximum efficiency in the lines. Adding insulation on piping and feed water systems will further reduce wasted heat. Installing an instant heat exchanger eliminated the need to fire up a boiler for one production process in an otherwise idle period.

Freybe has also reduced its water consumption. Polishing (i.e., physically filtering) water at the inlet to their refrigeration coolant loop, rather than using a chemical process, has reduced their water usage by 3500 cubic meters per year. By reducing the total organic waste going into their effluent in the first place, Freybe’s manufacturing wastewater is purer, and the cost of disposal of this collected waste (typically to landfill) is lowered. In addition, they are currently looking at the possibility of partnering with local food manufacturers to process their waste in an anaerobic digester, eliminating landfill-bound organic waste entirely.

Freybe’s fleet is also an area for big savings. Installation of GPS tracking is planned for all fleet vehicles. Originally, 10 one-ton vans were used by all local staff trips, from sales to deliveries and merchandising. In January 2011, they began replacing the five vans ordinarily used by sales reps with fuel-efficient vehicles. The deliveries of product are done in the remaining five one-ton vans: the plan is to replace them with more fuel-efficient 3 three-ton Hino Hybrid vehicles.

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