2024 Energy usage report – Phase 5

2024 Energy Usage Report – Phase 5

March 2026

Table of Contents

1. Introduction
2. Methodology

• Development of the Data Collection Tool
• Participation
• Data Collection and Validation
• Scope of Data Collection
• Key Metrics2.6 Data Quality and Anonymisation

3. Electricity Use Intensity Results

• Packing Operations
• Cold Storage Operations
• Controlled Atmosphere (CA) Operations
• Regular Atmosphere (RA) Operations

4. Overall Packhouse Electricity Use Intensity Results

• Results
• Key Observations

5. Packhouse Electricity Sources

• Results
• Key Observations

6. Distribution of Packhouse Electricity Consumption

• Results
• Key Observations

7. Financial Impact

• Results
• Key Observations
• Cost of Electricity per Source

8. Year-on-Year Analysis

• Analysis of 5-Year Performance Trends
• Key Observations (2020–2024)

9. Energy Management Practices

• • Pre-sort/Packing Line
  • Refrigeration
  • Ablutions, Canteens, and Offices

10. Energy Cost Efficiency Matrix
11. Conclusion
12. Recommendations
13. Bibliography

Table of Figures

• Figure 1: Total kWh per tonne packed
• Figure 2: Cold Storage (CA + RA) Electricity Use Intensity
• Figure 3: CA Operations Electricity Use Intensity
• Figure 4: RA Operations Electricity Use Intensity
• Figure 5: Total Electricity Use Intensity
• Figure 6: Electricity Source Allocation
• Figure 7: Electricity Use Profile
• Figure 8: Electricity Cost (per kWh)
• Figure 9: Electricity Cost per Source
• Figure 10: Total Electricity Use Intensity
• Figure 11: Yearly Electricity Source Allocation
• Figure 12: Energy-saving practices in Pre-sort/Pack line
• Figure 13: Energy-Saving practices in Refrigeration
• Figure 14: Energy-saving practices in Ablutions, Canteen & Offices
• Figure 1: Energy cost efficiency matrix

List of Tables

• Table 1: Data Quality

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 was commissioned by the Packhouse Action Group to study electricity consumption in Western Cape pome fruit packhouses and cold storage facilities, beginning with 2020 data and evolving into a long-term benchmarking project. This fifth phase report presents the 2024 results and builds on the 2023 findings, which highlighted rising energy costs and increased load-shedding affecting the industry.

2. Methodology

The methodology for this phase (Phase 5) remains consistent with the rigorous approach established in previous years to ensure data comparability and integrity. The study focuses on quantifying electricity consumption and costs across specific functional areas of pome fruit operations.

2.1 Development of the Data Collection Tool

Data was collected using the established Excel-based collection tool. The Phase 5 tool incorporated refinements to support the evolving needs of the project:

• Historical Data Integration
• Electricity Management Quantification

2.2 Participation

Previous participants were re-engaged and new packhouses were contacted via phone, email, and WhatsApp, resulting in 11 returning participants and two new participants out of 36 contacted, while others did not participate mainly due to limited data collection capacity, lack of metering, and time or resource constraints.

2.3 Data Collection and Validation

Electricity consumption, cost, and source data were collected through a standardised data collection tool. To ensure high data quality, the following steps were taken:

• New participant onboarding
• Data collection tool sharing
• Sense Checking
• Data Validation
• Cost Accuracy

2.4 Scope of Data Collection

To provide granular insights, energy use was investigated across three distinct areas within pome fruit packhouses:

1. Packhouse Operations
2. Controlled Atmosphere (CA) Operations
3. Regular Atmosphere (RA) Operations

2.5 Key Metrics

The primary metric used to evaluate efficiency is Electricity Use Intensity (EUI). This is defined as:

• Packing EUI
• Cold Storage EUI

2.6 Data Quality and Anonymisation

As in previous phases, all packhouse data is anonymised and categorised by quality—metered, estimated, or no data—based on the method of data collection, with Table 1 outlining the data quality for each participating operation.

3. Electricity Use Intensity Results

3.1 Packing Operations

The energy efficiency of packing lines remains a core benchmark for operational success, representing the electrical load required to move fruit through all packing stages.

3.2 Cold Storage Operations

Cold storage remains the most energy-intensive component of packhouse operations, driving the majority of electricity demand.

4. Overall Packhouse Electricity Use Intensity Results

The overall electricity intensity metric (kWh per tonne of fruit packed) provides a high-level view of a packhouse’s energy efficiency by combining electricity used for packing, refrigeration (CA and RA), and administrative operations, excluding non-core consumption. While this metric indicates general energy use per unit of fruit packed, results should not be directly compared between packhouses due to differences in operational practices.

4.1 Results

The results show a wide range of electricity intensities, from 71 to 327 kWh per tonne of fruit packed. Among packhouses with verified metered data (A and B), the overall electricity use intensity ranged from 205 to 282 kWh per tonne, while results from other packhouses are based on estimates and should be interpreted with caution.

• Top Performers
• Historical Benchmarks
• High-Intensity Operations
• Corrective Trends

4.2 Key Observations

The 2024 results for overall electricity intensity reveal a maturing energy landscape where strategic investments and operational refinements are yielding measurable results.

• Emergence of High-Efficiency Benchmarks
• Industry Mean
• Correction of Historical Outliers
• Throughput Sensitivity

5. Packhouse Electricity Sources

The energy landscape for packhouses in 2024 continues to evolve as packhouses balance cost, reliability, and sustainability. This section analyses the breakdown of electricity sourced from the national grid, renewable installations, and diesel generators.

5.1 Results

The 2024 data highlight a significant shift toward mixed energy models, with a growing percentage of total consumption being met by on-site renewable generation.

• Grid Dominance
• Renewable Integration
• Generator Reliance

5.2 Key Observations

• The Rise of Solar
• Resilience Planning
• Cost Implications

6. Distribution of Packhouse Electricity Consumption

Analysing the distribution of electricity consumption across different operational areas provides vital insights for targeting energy reduction strategies. This section breaks down the 2024 usage into four primary categories: Packhouse Operations, CA Operations, RA Operations, and Other (non-production, e.g. housing) uses.

6.1 Results

The 2024 data confirms that refrigeration (CA and RA) remains the dominant energy consumer across almost all participating packhouses.

• Refrigeration Dominance
• Operational Variability
• Packhouse Operations
• Other (Non-Production) Loads

6.2 Key Observations

• Refrigeration as the Primary “Hotspot”
• The RA-Only Profile
• Strategic Opportunity

7. Financial Impact

The financial impact of electricity consumption is a primary concern for packhouse management, especially given the persistent upward trend in national utility tariffs.

7.1 Results

The total electricity cost comprises the cost of grid electricity, renewable energy, and diesel used in generators.

• Grid Electricity Costs
• Renewable Energy Savings
• Generator Expenditure
• Data Incompleteness

7.2 Key Observations

• Renewable Return on investment
• Grid Inflation
• Impact of Reduced Load Shedding
• The “Generator Trap”
• Strategic Shift

7.3 Cost of Electricity per Source

To understand the drivers behind the cost of electricity per source it is necessary to analyse the individual rates of the three primary energy streams. The 2024 data highlight the massive price variance between utility-provided power, self-generation via renewables, and emergency diesel backup.

8. Year-on-Year Analysis

8.1 Analysis of 5-Year Performance Trends

The five-year data horison shows a maturing energy landscape where many packhouses are successfully stabilising their consumption despite increasing operational complexities. It should be noted that gaps in the historical record for certain packhouses reflect years where they did not participate in the benchmarking study.

• Long-Term Efficiency Leaders
• Most Improved
• Consistency and Stabilisation
• Rising Intensities

8.2 Key Observations (2020–2024)

• Project participation
• Normalisation of the Industry Average
• Electricity Source Allocation (2020–2024)
• Grid Electricity
• Renewable Energy Surge
• Generator Resilience

9. Energy Management Practices

It is important to move beyond simply tracking consumption to understanding the specific operational behaviours and technologies driving these results. All participating packhouses now consistently employ energy-saving practices across their operations, reflecting a maturing commitment to efficiency within the industry.

9.1 Pre-sort/Packing Line

The pre-sorting and packing lines represent a significant portion of the electricity use of a packhouse.

• LED Lighting
• Variable Speed Drives (VSDs)
• Programmable Logic Controllers (PLCs)
• Energy Efficient Motors
• Behavioural Savings

9.2 Refrigeration

Refrigeration is the primary driver of electricity demand in pome fruit operations, refrigeration (combined CA and RA operations) accounted for between 65% and 94% of total energy use in the 2024 reporting period.

• Variable Speed Drives (VSDs)
• Programmable Logic Controllers (PLCs)
• High-Speed Doors
• Maximum Demand Controllers
• SCADA Systems

9.3 Ablutions, Canteens, and Offices

While often categorised as secondary loads, the energy consumption in administrative and staff support areas provides a significant opportunity for “low-hanging fruit” efficiency gains.

• LED Lighting
• Hot Water Boiler Management
• Motion Sensors (Smart Switches)

10. Energy Cost Efficiency Matrix

This analysis examines the relationship between physical energy intensity (kWh per tonne packed) and financial intensity (Energy cost in ZAR per tonne packed). By mapping these two metrics, we can identify which packhouses are successfully converting efficient energy use into lower operational cost.

• Financial Leaders
• The Cost of Inefficiency
• The Renewable Buffer

11. Conclusion

• The Normalisation of Efficiency
• The Renewable “Shield”
• Cold Storage Benchmarks

12. Recommendations

To further improve energy use performance, packhouse management should prioritise the following strategic actions:

Infrastructure:

• Universal Sub-metering

Financial Strategy: Source Optimisation

• Maximise Renewable Energy Use

Operational Culture: The Human Element

• Behavioural Governance

Futureproofing

• Carbon Reporting

Recommendations for Data Collection Tool Enhancements

To provide deeper diagnostic insights in future project cycles, we recommend adding the following specific data fields to the collection tool:

• Fruit Waste and Yield Analysis
• Cold Storage Volume (m3)