Enews signup

Decas Cranberry Reaps Benefits from Boiler Equipment Upgrades

Case Study

  • Company: Decas Cranberry
  • Industry: Food & Beverage
  • Location: Carver, Massachusetts
  • Profile: The plant was running at capacity with their current boiler system.
  • Challenge: Utilize utility rebate incentives to bring their boiler system to proper capacity, while maximizing energy savings solutions.
  • Solution: Perform a BOOST (Boiler Operation Optimization Savings Test) analysis on the existing boiler room solution to meet their steam and sustainability needs. The report recommended an upgrade to existing boiler equipment for reduced fuel usage and NOx emissions.
  • Results: Decas Cranberry will emit 4,620 fewer metric tons of CO2 into the environment and save more than $1 million in energy costs over the next 10 years.

Decas Cranberry Products, Inc., is the second largest processor of sweet dried cranberries in the world. Its facility, located in Carver, Mass., processes more than 50 million pounds of cranberries annually to produce products that include: cranberry concentrate, sweetened dried cranberries, cranberry extract powders
and oils, and fresh cranberries.

In 2010, according to Decas Cranberry Facility Manager Mike Janick, the plant was nearing capacity on its 1998 Cleaver-Brooks CBLE 500 hp boiler. At the same time, National Grid, the local gas utility, was awarding rebate incentives to companies that increased their energy efficiency. As a result, Janick contacted Robert Cifello, aftermarket manager at Frank I Rounds Company, to explore the facility’s boiler room options.

Cifello conducted an energy audit, utilizing the proprietary BOOST (Boiler Operation Optimization Savings Test) software program available from Cleaver-Brooks. The customizable computer program generates a variety of financial metrics showing which upgrades, retrofits or replacements maximize a company’s energy-saving and environmental goals.

Using information specific to the facility, Cifello presented retrofit options that would increase Decas Cranberry’s energy efficiency and reduce its carbon footprint. He recommended that the facility install the advanced Hawk integrated control system and a stack economizer.

By adding the Hawk control system to its existing boiler, Decas Cranberry could realize an energy savings of 6.1% annually and reduce CO2 by 462 metric tons and NOx by 6%. Based on the anticipated savings, the plant would recoup its equipment cost within eight months.

Cifello also presented Decas Cranberry with the financial data to support adding a stack economizer to its boiler. The economizer would increase energy savings by 1.6% and further reduce CO2 by 120 metric tons and NOx by 2%.

Janick decided to do the two upgrades together to maximize savings and turnaround time. The new control system and economizer were installed during facility’s holiday break in December 2010.

“We are able to maintain water levels in the flash tanks much more effectively. Prior to the installations, we were experiencing a lot more surging, and now the unit responds more efficiently.” - Mike Janick, Plant Manager

See what Michael Janick has to say in this YouTube video about Cleaver-Brooks and Frank I. Rounds, the Cleaver-Brooks representative for Decas Cranberry. Following the upgrades, Janick said the boiler runs much more efficiently. He added, “The control used to go from low to high fire to meet plant demands. Now,
it stays within operating variance in loads. Also, we are able to maintain water levels in the flash tanks much more effectively. Prior to the installations, we were experiencing a lot more surging, and now the unit responds more efficiently.”

Janick is also pleased with the environmental benefits of the upgrades. He said, “Being a food manufacturer and an agriculture-based company, improving our carbon footprint is a consideration in many of the projects that we do.”

By adding the Hawk control system and stack economizer to its boiler, over the next 10 years, Decas Cranberry will emit 4,620 fewer metric tons of CO2 into the environment and save more than $1 million in energy costs.