J.R. Simplot Company: New Potato Processing Plant

Background

J.R. Simplot’s showcase project is a new, 420,000 square foot, state-of-the-art potato processing plant that will integrate innovative energy-efficient technologies to achieve dramatic energy efficiency improvements of up to 25% while producing hundreds of millions of pounds of frozen potato products per year. Once built, the plant is expected to save the company millions of dollars and contribute to its goal of reducing energy intensity by 25% over 10 years.

The new mega-factory will consolidate the operations of three aging facilities and achieve economies of scale in the production of frozen French fries, formed, and shredded potatoes. J.R. Simplot invested large amounts of capital in this facility to adapt to the changing requirements for maintenance, environmental compliance, and modernization. After breaking ground in 2012, the new factory is expected to be fully operational in early 2014. The new plant is expected to be about 25% more energy efficient on average than the three plants it is replacing.

Solutions

New technologies will upgrade the factory’s energy performance with improvements throughout the plant’s refrigeration systems and improved pipe insulation. Compressed air systems will feature a centrifugal compressor, master controller to ensure efficient compressor sequencing, and an oversized receiver to reduce peak electric demand during high usage air events. New regenerative thermal oxidizer, boiler stack, and fryer exhaust technologies will recover heat more efficiently.

The J.R. Simplot Engineering staff worked with Burns & McDonnell Engineering staff, as well as a design-build contractor (Republic), to identify energy efficiency features in the major energy-using systems. The group identified the following features for inclusion in the final design based on energy savings and project costs:

Refrigeration system features

Economizer flash vessel and efficient defrost
Condenser fan motor VFD
Raised low stage suction pressure
Pre-cool process load reduction using process water
Thicker pipe insulation
Evaporator fan VFDs
Economized refrigerated air handlers

Compressed air features

Centrifugal compressor
VFD control for trim compressors
Cycling refrigerated dryer
Master controller to ensure efficient compressor sequencing
Demand expander to ensure a constant header pressure
Oversized receiver to reduce the peak electric demand during high usage air events

Lighting

Solar powered LED exterior lighting

Heat recovery systems

Systems are being installed to recover heat from the plant’s regenerative thermal oxidizer, boiler stack and fryer exhaust

J.R. Simplot Company: New Potato Processing Plant

ANNUAL ENERGY USE

(Source EUI)

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ANNUAL WATER COST

ANNUAL PLANT ELECTRICITY USE

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IN BUILDING ENERGY USE

IN BUILDING ENERGY COST

ACROSS NETWORK USE

ACROSS NETWORK COST

ANNUAL EMISSIONS

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J.R. Simplot Company: New Potato Processing Plant

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