2024_PAG Energy Project_Phase 4_Report_Final

2023 Energy Usage Results

May 2025

Table of Contents

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

List of Abbreviations

• CA: Controlled Atmosphere
• CAPEX: Capital Expenditure
• GWh: Gigawatt-hours
• kWh: Kilowatt-hours
• LED: Light-Emitting Diode
• OPEX: Operational Expenditure
• PLC: Programmable Logic Controller
• PPA: Power Purchase Agreement
• RA: Regulated Atmosphere
• VSD: Variable Speed Drive

Definitions

• Energy use intensity (EUI): Measures energy used to produce a unit of output. Lower EUI = 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, etc.).
• Electricity Consumption: Amount of electrical energy used to power devices/equipment.

Introduction

Since 2021, Blue North Sustainability (Pty) Ltd. has conducted annual studies for the Packhouse Action Group (PAG) on electricity consumption in pome fruit packhouse and cold storage operations. This report presents the fourth round of results (2023 data), with objectives to:

• Replicate previous electricity use studies
• Conduct year-on-year electricity use intensity comparisons
• Collect and analyse data on energy sources and cost
• Summarise energy management practices
• Simplify data collection and validation

Water usage results are available in a separate report.

Methodology

Development of the Data Collection Tool

• Data collected: electricity consumption, cost, source, and energy management practices.
• Data was sense-checked for consistency and accuracy.
• Anomalies were discussed and rectified where possible.
• Phase 4 improvements:
  • Incorporated Phase 3 data for validation
  • Improved renewable energy cost and installation fields
  • Enhanced generator efficiency calculation

Scope of the Data Collection

Three areas investigated for energy use intensity:

• Packhouse operations: All operational electricity (pre-sorting, packing lines, ablutions, canteens, offices)
• Controlled Atmosphere (CA) operations: Electricity for CA (refrigeration plant, compressors, condensers, fans, cooling towers)
• Regulated Atmosphere (RA) operations: Electricity for RA (refrigeration plants, compressors, condensers, fans, cooling towers)

Participation

• 32 packhouses contacted; 9 provided data (all previous participants)
• 2 did not participate but showed future interest; 1 new packhouse interested for future
• 12 did not respond; 10 declined
• Main reasons for non-participation: limited capacity, insufficient record-keeping, limited resources

Data Quality and Notes on the Data

• All datasets for Phase 4 are for the 2023 calendar year.
• All kWh figures include grid, PV (solar), and generator electricity.
• Packhouses are anonymised (A to P).
• Data quality is best for grid electricity (from invoices); less reliable for generator/solar.
• Allocation of electricity to operations is sometimes estimated.

Table 1: Summary of Packhouse Data Quality

Electricity Use Intensity Results

Packing Operations

• Calculation:
  Packing operations electricity consumption (kWh) / Tonnes of pome fruit packed
• Results:
  Metered data: 12–22 kWh/tonne (similar to previous phase). All packhouses use energy-saving measures.

Cold Storage Operations

• Calculation:
  Cold (CA + RA) storage operations electricity consumption (kWh) / cold (CA + RA) storage tonne.days
• Results:
  Wide variation due to estimation. Accurate metering is needed for improvement.
  • Example: 200 tonnes stored for 3 days = 600 tonne.days.
• Energy-saving practices:
  • Solar panels (B)
  • VSDs on compressors (C)
  • High-speed doors and room management (M)

Controlled Atmosphere Operations

• Calculation:
  CA operations electricity consumption (kWh) / CA tonne.days
• Results:
  Packhouse A: 0.7 kWh/tonne.day (aligns with benchmarks).

Regular Atmosphere Operations

• Calculation:
  RA operations electricity consumption (kWh) / RA tonne.days
• Results:
  Packhouse A: 7.7 kWh/tonne.day (below benchmark).

Overall Packhouse Electricity Use Intensity Results

• Combines all measured electricity use for production activities.
• Average (excluding outlier): 206 kWh/tonne packed (down from 220 kWh in 2022).
• Direct comparison between packhouses is limited due to operational differences.

Packhouse Electricity Sources

• Main sources: grid, solar (PV), diesel generators.
• Grid supplies ~76% of electricity on average.
• 8 packhouses use renewable energy.
• Generator reliance increased due to load shedding.

Packhouse Electricity Use Profiles

• CA and RA storage operations consume more electricity than packing operations.
• Average split (excluding G): 39% RA, 46% CA, 15% packing.
• Data quality varies due to incomplete metering and allocation.

Electricity Cost

Total Electricity Cost per kWh

• Includes grid, renewable, and generator costs.
• Renewable energy cost: OPEX + financing (interest on CAPEX).
• Formula:
  (Grid cost + Generator fuel cost + Renewable OPEX + Renewable CAPEX interest) / Total kWh
• Average cost (excluding outlier): R2.25/kWh (up from R1.63/kWh in 2022).

Electricity Cost per Source

• Renewable energy is least expensive; generators are most expensive.
• Average grid electricity cost: R2.38/kWh (up from R1.87/kWh in 2022, due to tariff hike).
• Data sources: Eskom/municipal invoices, packhouse meters, financial statements.
• Generator efficiency:
  • Scania: 0.13–0.36 litres diesel/kWh
  • Volvo: 0.12 litres/kWh (best)
  • John Deere: 0.96 litres/kWh (worst, older model)

Year-on-Year Analysis

• Load shedding increased dramatically in 2023 (21,715 GWh shed over 332 days).
• Greater reliance on generators and renewables.
• Some packhouses (B, K, L, M) show decreasing electricity use per tonne packed.
• Others (G, H, P) show increases, often due to lower packing volumes (weather impacts).
• Cold storage intensity trends vary; further investigation needed.
• Overall, grid electricity use dropped by 19% between 2022 and 2023.

Energy Management Practices

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

Refrigeration

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

Ablutions, Canteens, Offices

• Most use LED lights
• Some use motion sensors
• Many switch off hot water boilers over weekends

Additional Energy-Saving Practices

• Smart switches (G)
• Timers for cooling fans (H)
• Power factor correction and energy monitoring (K)
• Plant room shutdowns (L)

Cost Savings

• Five packhouses reported average savings of R2,078,984 (1.293 GWh) per packhouse from energy efficiency measures.

Conclusion

• Continued value from annual energy use reporting.
• Improved data quality and more accurate renewable energy cost calculations.
• All participants now employ energy-saving practices across all areas.
• Increased reliance on solar is a positive trend.
• Accurate metering and record-keeping remain challenges, especially for cold storage.
• Ongoing participation and improved data collection are key for future progress.

Recommendations

For Industry

• ESG Reporting:
  Require packhouses to report overall energy use and use per source.
• Metering Campaign:
  Promote consistent metering and data integrity.
• “Energy Heroes” Initiative:
  Recognise and incentivise energy efficiency.

For Data Collection

• Diagnose metering challenges and support improvements.
• Gather participant feedback to improve tools.
• Continue annual data collection for trend analysis.
• Collect standardised cold storage protocol data.

For Packhouses

• Metering:
  Install submeters for better data and hotspot identification.
• Record-Keeping:
  Track tonnages and cold storage durations.
• Energy-Saving Measures:
  • Maintain refrigeration systems
  • Use occupancy sensors
  • Maintain ventilation systems
  • Improve building insulation
  • Promote behavioural change for energy savings
• Renewable Energy:
  • Evaluate on-site generation
  • Consider power purchase agreements (PPAs)
  • Advocate for supportive policies

By following these recommendations and participating in data collection, packhouses can reduce environmental impact and improve energy efficiency. Ongoing analysis will help identify further improvements and measure effectiveness year-on-year.