PAG Water and Energy Project: 2023 Energy usage results

2023 Energy Usage Results

May 2025

Table of Contents

1. Introduction
2. Methodology
   • Development of the Data Collection Tool
   • Scope of the Data Collection
   • Participation
   • Data Quality and Notes
3. Electricity Use Intensity Results
   • Packing Operations
   • Cold Storage Operations
   • Controlled Atmosphere Operations
   • Regular Atmosphere Operations
4. Overall Packhouse Electricity Use Intensity Results
5. Packhouse Electricity Sources
6. Packhouse Electricity Use Profiles
7. Electricity Cost
   • Total Electricity Cost per kWh
   • Electricity Cost per Source
8. Year-on-Year Analysis
9. Energy Management Practices
   • Pre-sort/Packing Line
   • Refrigeration
   • Ablutions, Canteens and Offices
   • Additional Energy-Saving Practices
   • Cost Savings from Energy Saving Practices
10. Conclusion
11. Recommendations

List of Figures

• Figure 1: Electricity use intensity of the Phase 4 participant packing operations
• Figure 2: Cold storage electricity use intensity for Phase 4 participants with estimated data
• Figure 3: Electricity use intensity of the CA operation of Packhouse A
• Figure 4: Electricity use intensity of the RA operation of Packhouse A
• Figure 5: Total electricity intensity
• Figure 6: Electricity sources per packhouse
• Figure 7: Electricity usage profile per packhouse
• Figure 8: Electricity cost for each packhouse
• Figure 9: Cost per electricity source for each packhouse
• Figure 10: Generator electricity source allocation by model
• Figure 11: Generator efficiency per model
• Figure 12: Year-on-year comparison of packing operations electricity use intensities
• Figure 13: Year-on-year comparison of cold storage operations energy use intensities
• Figure 14: Year-on-year comparison of overall packhouse electricity use intensities
• Figure 15: Year-on-year comparison of electricity sources
• Figure 16: Energy-saving practices applied in the presort and packing line
• Figure 17: Energy-saving practices in the refrigeration operations
• Figure 18: Energy-saving practices in ablutions, canteens and offices

List of Tables

• Table 1: Summary of packhouse data quality for the different areas/activities

List of Abbreviations

Definitions

• Energy use intensity (EUI): Measures energy used per unit of output. Lower EUI means higher efficiency. Includes all energy forms.
• Electricity use intensity: Focuses on electricity used per unit of output.
• Energy Consumption: Overall use of energy resources (fuels, electricity).
• Electricity Consumption: Amount of electrical energy used.

1. Introduction

In 2021, Blue North Sustainability (Pty) Ltd. was contracted by the Packhouse Action Group (PAG) to study electricity consumption in pome fruit packhouse and cold storage operations. This report presents Phase 4 results (2023 data), comparing with previous phases and summarising energy management methodologies.

2. Methodology

2.1 Development of the Data Collection Tool

Data on electricity consumption, cost, and source was collected via a tool. Additional questions covered energy management practices. Data was sense-checked and anomalies discussed with participants.

2.2 Scope of the Data Collection

Three areas investigated:

• Packhouse operations (pre-sorting, packing lines, ablutions, canteens, offices)
• Controlled Atmosphere (CA) operations
• Regulated Atmosphere (RA) operations

2.3 Participation

• 32 packhouses contacted, 9 provided data (all previous participants).
• Reasons for non-participation: limited capacity, lack of record-keeping, limited resources.

2.4 Data Quality and Notes

See Table 1 for summary. All datasets correspond to 2023. All kWh figures include grid, PV (solar), and generator electricity. Packhouses are anonymised (A to P).

3. Electricity Use Intensity Results

3.1 Packing Operations

Calculation:
Packing operations electricity consumption (kWh) / Tonnes of pome fruit packed

Results:
Metered data ranged between 12 to 22 kWh/tonne. All packhouses employ energy-saving measures.

3.2 Cold Storage Operations

Calculation:
Cold (CA + RA) storage operations electricity consumption (kWh) / cold (CA + RA) storage tonne.days

Results:
Electricity use varied significantly. Accurate metering is needed for improvement.

3.3 Controlled Atmosphere Operations

Calculation:
CA operations electricity consumption (kWh) / CA tonne.days

Results:
Packhouse A: 0.7 kWh/tonne.day (metered data).

3.4 Regular Atmosphere Operations

Calculation:
RA operations electricity consumption (kWh) / RA tonne.days

Results:
Packhouse A: 7.7 kWh/tonne.day (metered data).

4. Overall Packhouse Electricity Use Intensity Results

Average electricity use per tonne of fruit packed in 2023: 206 kWh (excluding outlier). This is a decrease from 220 kWh in 2022.

5. Packhouse Electricity Sources

Grid electricity is the main source (76%). Eight packhouses use renewable (solar) energy.

6. Packhouse Electricity Use Profiles

CA and RA-storage operations consume more electricity than packing operations. Improving data collection and metering is recommended.

7. Electricity Cost

7.1 Total Electricity Cost per kWh

Average cost in 2023: R2.25/kWh (increase from R1.63/kWh in 2022).

7.2 Electricity Cost per Source

Generator electricity is most expensive; renewable energy is least expensive. Average grid electricity cost per kWh for 2023: R2.38.

8. Year-on-Year Analysis

Load shedding increased reliance on generators. Some packhouses showed decreasing trends in electricity use intensity due to energy-saving practices.

9. Energy Management Practices

9.1 Pre-sort/Packing Line

• 67% use energy-efficient motors
• 89% have LED lights
• 78% use VSDs
• 67% have PLCs
• 33% switch off lights during breaks

9.2 Refrigeration

• All have VSD motors on compressors/fans
• 78% use PLC programs for condensers
• 44% use SCADA systems
• 67% have high-speed doors
• 55% use maximum demand controllers

9.3 Ablutions, Canteens and Offices

• Seven use LED lights
• Two use motion sensors
• Six switch off hot water boilers over weekends

9.4 Additional Energy-Saving Practices

• Smart switches, timers, power factor correction, energy monitoring, plant room shutdowns

9.5 Cost Savings

Five packhouses estimated average savings of R2,078,984 (1.293 GWh) per packhouse.

10. Conclusion

Consistent participation and improved data collection have enhanced insights. Widespread adoption of energy-saving practices and increased use of solar energy are positive trends. Accurate metering remains a challenge.

11. Recommendations

Industry ESG Reporting

• Report overall energy use [kWh]
• Report energy use per source [kWh]

Industry-Wide Action

• Launch metering campaign
• Implement “Energy Heroes” recognition program

Data Collection Improvements

• Diagnose metering challenges
• Solicit participant feedback
• Continue annual data collection
• Gather cold storage protocol information

Packhouse Actions

• Install submeters
• Record tonnages and storage duration
• Optimise refrigeration systems
• Install occupancy sensors
• Maintain ventilation systems
• Improve building insulation
• Promote behavioural change programs

Renewable Energy Integration

• Evaluate on-site renewable generation
• Consider PPAs
• Advocate for renewable energy policies

By following these recommendations and participating in the data collection process, packhouses can reduce environmental impact and improve energy efficiency. Ongoing analysis is crucial