Background:

Manufactures a variety of frozen and chilled meals

Freezers have been replaced since the base year and a new packing line has been installed.

No formal monitoring of energy data and no sub-meters on site.

General shift towards frozen products and products that are cooked twice (see process flow diagram below).

Defining Production Variables:

Output has not decreased, therefore Common Approach 1 is not applicable.

Key issue to reduce the number of variables!

• Early thoughts were to split by frozen and chilled, however, need to take account of ‘double cooked’ products.

• Five different energy intensity products identified: frozen long cook, frozen short cook, chilled long cook, chilled short cook, and double cooked.

• The base year values for each of the five product groupings can be identified

Approach and Action Plan:

Follow Common Approach 2 to derive the PMOA and simple example 2B to adjust the target.

After 30 days briefly analysis the data and ensure that the production variables have been correctly defined.

Ensure that the majority of products have been made during the two month period (e.g. be aware of capturing data for seasonal products).

Prepare text for the PMOA pre-approval document using the dummy submission document for Common Approach 2.

Background:

Manufactures loaves of bread and a variety of other bakery products

Additional ovens installed since the base year and air conditioning has been installed in one production hall.

Gas meters are present on all ovens, however, no electricity sub-metering exists (see diagram overleaf).

Weekly production and metered energy data is available from May 2001 onwards.

There has been a slight decrease in the total output of the site and a general shift towards more energy intensive products

Defining Production Variables:

Output has not decreased and therefore could try Common Approach 1, however, we do know that product mix is very important.

Approach:

(a) Attempt to undertake Common Approach 1 with total output.

(b) Try Common Approach 2 on Electricity and Gas against the six product variables (A to F inclusive).

Try further analysis if required:

(c) Multiple Regression Analysis (MRA) (as undertaken in Common Approach 2) on Bread Oven Gas against products A and B;

(d) MRA on Other Products Oven Gas against products C, D, E and F;

(e) MRA on boiler gas against six production variables;

(f) Analysis of space heating gas against total output and degree days

Results:

Approach (b) – Poor correlation coefficient for gas (0.37) and one constant in the MRA was negative (which in reality means that the more of a product that you make, the less energy it takes to make it, and this is of course highly unlikely to be the case). Electricity analysis gave a better R² value of 0.65. May need to re-define the production variables into different product types.

Approach (c) – Poor correlation on bread oven gas against products A and B, R² = 0.65.

Approach (d) - R² = 0.27 and one constant was a negative value.

No further analysis can be undertaken until the product types have been more appropriately defined to improve the R² values

Background:

Manufactures a variety of ambient foods.

New effluent plant and air emissions abatement equipment installed since the base year (5 – 10% increase in energy consumption).

Historical monthly (calendar) total electricity and gas data available.

Weekly production data available.

Extensive sub-metering installed but not yet recorded.

24 hour manufacture of all products, i.e. constant production process.

CHP plant on site.

Shift towards energy intensive products that represent 90% of the total energy used on site but only represent 60% of the total production

Defining Production Variables:

Output has decreased slightly since the base year.

Area 1: one core production process with additional processing to make 3 products.

Area 2: 1 product only.

Area 3: numerous different products, generally same production process but very low energy user compared to other products, therefore, treat as 1 product only.

Base year tonnages for all product types have been reported

Approach and Action Plan:

No immediately useful historical data because the energy data if for calendar months and the production data is weekly.

Start a campaign of collecting daily energy and production data. Energy data must include electricity generated by the CHP plant. Record the sub-metering on the new environmental abatement equipment.

Start by following Common Approach 2 with five production variables.

Combine Common Approaches 2 and 5 if 2 alone is unsuccessful. Common Approach 5 will compensate for the additional environmental equipment and Regulatory Constraints can be applied.

Prepare evidence to apply Regulatory Constraints and ensure that the site complies with the Qualitative Requirements.

Prepare text for the PMOA submission to DEFRA