Articles & Case Studies

Carlsberg UK selects eSight® M&T solution and reduces energy consumption by 10%

Posted: Wednesday 9th February 2011

Backed by more than 150 years of Danish heritage, Carlsberg is a household name in the United Kingdom and Europe. Carlsberg UK is a subsidiary of the Carlsberg Group and is the UK's fourth largest brewer. Carlsberg UK currently employs around 1,800 staff across 16 sites in the UK.

Carlsberg UK required a web based Monitoring & Targeting (M&T) System for multiple plants and distribution depots throughout the UK.

The brewery was looking for a system that could import and calculate weekly KPI data against targets for multiple utilities including but not limited to: gas, water & electricity, as well as analyse production data and calculate plant efficiency.

Carlsberg UK also required the ability to manage data imports from a wide range of meters to incorporate complex production procedures in place across the brewing process. This had to be intuitive for access by non-technical users of the system

In addition, Carlsberg UK needed an energy solution to distribute a range of use alarms and average usage alarms automatically via email.

Carlsberg UK also needed a solution to display hourly dashboards at department operator level to monitor usage when the plant is running, stopped, shutdown and during maintenance periods.

The solution

Carlsberg UK chose eSight to manage energy usage throughout the brewing process to enable them to monitor the efficiency of their brewing processes and optimise for best performance, thus saving on bottom line costs.

Activities such as generation of compressed air and excessive water usage required in the brewing industry are easily monitored and optimised using eSight.

Carlsberg UK uses eSight to monitor the plant for shutdown opportunities. eSights alarm module generates range and average alarms to be sent via email to alert high usage in specific meters. The alarms are linked to production allowing for early reaction and quick intervention times to process and reduce losses. This can have a major impact on utilities costs, environmental compliance and production output.

The eSight system is managed by the Carlsberg UK onsite systems team. The use of eSight is coordinated and facilitated to user departments by the Energy Centre Manager & the Water and Effluent Continuous Improvement Manager.

Carlsberg UK holds a weekly meeting with user departments to review eSight dashboards. The weekly KPI data is calculated in eSight and compared to targets. This allows for changes to be made to enhance productivity and therefore achieve energy savings.

Benefits of using eSight

Since implementing eSight, Carlsberg UK has achieved a number of energy saving goals. Just some of the energy savings made since implementing eSight include:

h Reduced overall energy consumption by 10%

h Improved recovered energy from brewing process which uses 60% of site usage

h Reduced site water consumption by 10%

h Reduced effluent cost by 16%

Reduction of overall energy usage was achieved by understanding consumption loads and matching with production periods. eSight has enabled Carlsberg UK to utilise the CHP plant and recover heat by matching to process demands which has improved recovered energy from the brewing process.

The eSight suite is used as primary measure at the production level, focusing on software and plant improvements. As a result, Carlsberg UK have experienced continuous improvement toward their root cause analysis.

Dashboards

The eSight Dashboard module enables the user to bring together essential energy information, charts or tables on a single page. Users may run up to four easily interchangeable screens side by side, with each screen automatically updating every minute.

The eSight Dashboard has been designed to enable companies to show information on a full screen, suitable for display in receptions or in public locations.

Configuration is made simple through step-by-step screens; users are able to select the preferred layout. Users may also choose how often the dashboard refreshes; key when monitoring real time data.

Carlsberg UK use the dashboard module to highlight areas of performance which are most important to them. They utilise hourly dashboards at department operator level to monitor usage when the plant is running, stopped, shutdown or during maintenance periods.




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