Case Study:

Water usage in the meat processing industry

Water usage Foyle Logo

The challenge:

The Foyle Food Group is a meat processing group that comprises 4 distinct and separate meat processing facilities to accommodate slaughtering, deboning and rendering with a capacity of 200,000 cattle per year. The annual energy spend across the group is in excess of €6M. It was vital to get an insight on water usage in each facility.

The Solution:

The initiative to install an Energy Monitoring and Targeting (eM&T) System at Foyle was lead by the group CEO who realised that it was imperative to get a granular view of electricity and water usage in each facility if they were to make a significant impact on reducing energy usage across the operation.

Key Features:

  • Electricity, water and temperature points were monitored extensively across all plants
  • Ability to integrate existing metering and instrumentation from third parties
  • Energy and temperature information was made available to management through energy dashboards 
  • KPIs were created to allow performance comparisons to be made relating energy usage to production
  • A range of custom reports were designed which would be relevant to various members of staff and delivered on a daily and weekly basis
  • Public dashboards were installed on the factory floor so that shift supervisors could monitor production related electricity and water usage
  • An easy and intuitive system was provided which allows managers to apportion cost to various processes and cost centres
  • Access to the system was provided for a total of 35 different users with access levels limited to their relevant function, from supervisors, to managers, to group level directors and the CEO

Report Card:

  • Significant savings in water use were identified which reduced water usage by 50% in one of the plants
  • Ongoing monitoring of data indicates a complete return on investment within year 1 of installation
  • The system is yielding
    significant savings through behavioural changes in production areas using live dashboards