Quaker Oats installs new fuel efficient boilers
As part of its compliance with a PepsiCo corporate mandate on resource conservation, the Quaker Oats Bridgeview Division food manufacturing plant has installed two Miura Boiler LX200 gas-fired steam boilers to reduce fuel and water consumption, increase energy efficiency, and cut emissions. The 400,000-sq-ft facility, located just west of Chicago, is where Pasta Roni and Rice-a-Roni are made.
As part of its compliance with a PepsiCo corporate mandate on resource conservation, the Quaker Oats Bridgeview Division food manufacturing plant has installed two Miura Boiler LX200 gas-fired steam boilers to reduce fuel and water consumption, increase energy efficiency, and cut emissions. The 400,000-sq-ft facility, located just west of Chicago, is where Pasta Roni and Rice-a-Roni are made. Steam from the two Miura boilers is used for manufacturing and for heating the plant during winter months.
“The efficiency of the Miura boilers has enabled us to realize a 20% reduction in fuel consumption, which amounts to a savings of approximately $80,000 a year,” says Terry Hronec, facility engineer at the Bridgeview Division. “The two 200-hp Miura boilers are so efficient that we've eliminated two older fire-tube boilers, a 750- and a 300-hp unit.”
Miura boilers are designed to produce steam in five minutes (or less) due to their so-called “once-through” design. This technology also produces BHP outputs comparable to much larger units, but with less water consumption and a more compact footprint, which can reduce new construction costs and better utilize existing boiler-room space.
“We poured a concrete pad and put in the necessary piping and valves for a third Miura boiler, which we will use as a back-up,” Hronec notes. “The pad for our three Miura boilers is actually smaller than the footprint for the one 300-hp boiler we're removing. Plus, we now have space to walk around the boilers, and the room is a lot cooler than it was with the old fire-tube boilers.”
In addition to their increased energy efficiency and smaller size, Miura boilers also feature a “green” design that reduces harmful emissions such as nitrous oxide (NOx). Miura Boiler's gas-fired/Low-NOx LX Series steam boilers are designed to eliminate 75% of the harmful emissions of standard gas-fired boilers. Miura Boiler's LX Series steam boilers also deliver a Low-NOx rating of 20 ppm (standard gas-fired boilers produce pollutants at a rate of 80 ppm).
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After almost a decade of uncertainty, the confidence of plant floor managers is soaring. Even with a number of challenges and while implementing new technologies, there is a renewed sense of optimism among plant managers about their business and their future.
The respondents to the 2014 Plant Engineering Salary Survey come from throughout the U.S. and serve a variety of industries, but they are uniform in their optimism about manufacturing. This year’s survey found 79% consider manufacturing a secure career. That’s up from 75% in 2013 and significantly higher than the 63% figure when Plant Engineering first started asking that question a decade ago.