Efficient Plant October 2021 - 27

feature | solution focus
Opposite. Ocean Spray's Lehigh Valley facility
operates 24/7 and produces 100,000 cases of
cranberry beverages daily.
Right. GE iFIX SCADA system coupled with WIN911
Advanced remote-alarm notifi cation software
ensure continuous plant operation is maintained.
Th is goal couldn't have been accomplished
with the originally specifi ed three, 800-hp
boilers. Company engineers thought they'd
need larger boilers for steam to pasteurize
juice concentrate, a complex and costly
system that the industry relied on for years.
Aſt er collaborating with an energy consulting
fi rm and conducting an audit at the
previous Bordentown plant to determine
exactly how much energy would be required
to manufacture 100-million gal. of juice
annually, a mid-design change incorporated
energy-effi cient equipment and building
design.
DRAMATIC SAVINGS
Savings were achieved through equipment
that cost millions less up front, cut the
plant's carbon emissions, and slashed its
gas bill. Switching from steam to a more
effi cient heat-recovery system reduced the
plant's energy consumption by 37%.
Lehigh Valley uses a hydronic-loop system
to deliver and recover process heat that
is fed to the plant HVAC system and eliminates
the need for steam to process juice.
Th e heat-recovery system is so effi cient that
the facility does not need to purchase fuel
for heating during winter months.
Th e savings are the result of several
technical factors that primarily involve
positive pressurization of the plant, meaning
the facilities are pressurized in a way
that prevents outside air from entering the
building. Th is has a big impact on heating
and cooling costs. At the time of construction,
the facility was the only juice plant in
North America that used hot water instead
OCTOBER 2021
of steam for the pasteurization process.
Ensuring safe and effi cient operations
is critical to the company. To help reduce
maintenance expenses and ensure minimal
unplanned equipment downtime, Ocean
Spray implemented an iFIX SCADA system
from GE Digital, San Ramon, CA (ge.com),
coupled with WIN-911 Advanced remotealarm
notifi cation soſt ware from WIN-911
Soſt ware, Austin, TX (win911.com), to
continuously monitor and provide data on
the various alarms throughout the Lehigh
Valley facility.
Used primarily by the maintenance
team and overseen by Joe Faller, Controls
Automation Engineer at the Lehigh plant,
WIN-911 and the iFIX SCADA monitor
fl ows, pressures, and temperatures in the
facility's loops, process loops, and wastewater
system, ensuring proper levels so that
the juice production is safe and meets the
company's standards for quality and safety.
At 10,000 gal. of juice produced per hour
and 100,000 cases every day, this is no small
task. When Faller and his team receive notifi
cation of an alarm through text messages,
they can quickly assess and resolve issues to
minimize potential impact.
" Th e soſt ware's alarm-escalation-hierarchy
feature helps our team know if there's a
possible issue, so we can respond and quickly
resolve the problem, " Faller explained.
Faller sets up alarms in the programmable
logic controller and sends them to iFIX,
which is integrated with the remote-alarm
notifi cation soſt ware. WIN-911 monitors
a vast array of critical process loops that
include three steam boilers, a 44 F cooling
loop, a 28 F cooling loop, and a heating
loop.
" Monitoring and providing notifi cation
when there are problems with equipment
that is not watched 24/7 is a huge benefi t for
our team. WIN-911 allows us time to rectify
these issues before they become problems, "
Faller said. Remote-alarm notifi cation
soſt ware helps ensure the beverage facility
remains operational 24/7. EP
For information, visit ge.com and win-911.com.
EFFICIENTPLANTMAG.COM | 27
http://www.ge.com http://www.win911.com http://www.ge.com http://www.win-911.com http://www.EFFICIENTPLANTMAG.COM
Efficient Plant October 2021

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