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SGS Produce Reduces Operating Costs By Installing Frigitek™ Controllers & EC Motors

SGS Produce is a full-service wholesale produce company operating out of Los Angeles, California.

The company operates a warehouse where produce is stored before being shipped out to various segments of the food industry. SGS runs evaporators 24 hours a day, 7 days a week to maintain optimal produce cold-storage temperatures in the warehouse.

 

THE PROBLEM

Running evaporator fan motors 24/7 for 365 days a year results in a huge energy bill. The cost of energy has been skyrocketing for the past 5 years, so clients like SGS president, Carole Shandler are always looking for ways to reduce expenses at their facilities.

 

THE SOLUTION

We prepared a savings analysis and found that by retrofitting the evaporator coils in one of their coolers with Frigitek™ Controllers & 1.5 HP EC Motors, SGS will save approximately $225,000 in the next five years. LADWP’s Frigitek™ incentive of $27,547.45 allowed this project to pay for itself in less than 6 months.

 

WHY FRIGITEK™ IS THE RIGHT SOLUTION

Frigitek™ motor controllers function by sensing the operational status of the cooling system and controlling the speed of the evaporator fans. By operating the fans at a low-speed when no cooling is called for, the fans circulate about 40% as much as normal and use only 10% as much energy without impacting cooling requirements. The addition of either the Frigitek™ Single or 3-Phase motor controller to an evaporator will increase energy savings by approximately 50% over what EC motors alone will provide.

 

For more information on Frigitek™ Electronically Commuted (EC) Motors and Controllers and how Carlisle Energy can save you money, please contact us directly at (714) 684-1766.

Calculating Cost of Electric Defrost Heaters vs. Costs of 2 Fan Motors Running 24/7


Step 1: Operating Costs of the Defrost Heaters

The evaporator coil has 6 face heaters. Each face heater consumes 1,824 watts. There is also one drain pan heater that draws 736 watts.

Heater Power:

(6 face heaters x 1,824 watts’/face heater) + (1 drain pan heater x 736 watts/drain pan heater) = 11,680 watts

The defrost clock runs 4 times a day, in 15 minute cycles. That’s a total run-time of 60 minutes a day. We can now use the total watts to calculate the energy consumption in watt-hours.

Heater Consumption:

11,680 watts * (1 hour) = 11.68 kWh per day = 355.3 kWh per month

The cost of electricity is $0.134 per kWh, so the true cost of the electric defrost heaters can be determined in the calculations below:

Heater operating cost:

355.3 kWh per month x ($0.134/kWh) = $47.61 per month

 

STEP 2: OPERATING COST OF THE (2) FAN MOTORS RUNNING 24/7

Fan motors power:

Volts per motor x Amps per motor x # of motors x Power factor (efficiency) x square root of three (for a 3-phase motor) = 460 Volts * 1 Amps * 2 * 0.83 * square root of 3 = 1,380 kW drawn by the fans

Fan motors consumption:

1,380 kW * 30.42 days/month = 1007 kWh per month = 12,089 kWh per year

The cost of electricity is $0.134 per kWh, so the true cost of the (2) fan motors running 24/7 can be determined below:

Fan motors operating cost = 12,089 kWh per year x ($0.134/kWh) = $134.99 per month

THE COST TO OPERATE THE (2) FAN MOTORS IS ALMOST 3 TIMES MORE THAN THE DEFROST HEATERS!

 

 

For more information on Frigitek™ Electronically Commuted (EC) Motors and Controllers and how Carlisle Energy can save you money, please contact us directly at (714) 684-1766.