Kodak Alaris cuts energy costs by 11%

Formed in 2013, born from one of the world’s most iconic brands, Kodak Alaris is known globally for manufacturing state of the art photographic and imaging equipment.

The challenge

Kodak Alaris was looking for ways to reduce energy costs and operational planning time at its manufacturing site. With a complex on-site generation set up, the company needed a strategy that used generation and consumption assets in the most efficient way. As with many manufacturers, creating this operational strategy can be a time consuming process, that often requires manual data-entry and complicated calculations. For Kodak Alaris, these were based on broad averages, rather than accurate Day Ahead half-hourly market information.

A practical, low-cost solution was needed, to help the company respond to market information more effectively.

The solution – Site Optimisation

Ørsted’s Site Optimisation is a cloud based solution. It uses sophisticated algorithms to calculate the optimal run schedule for an operating plant. To do this, it analyses market signals, such as wholesale energy prices, in relation to operating constraints and asset availability.

It then creates bespoke, daily run schedules that detail the commercially optimal way to operate equipment, schedule production, and generate electricity on-site or export to the grid. Run schedules are accessed via Kodak Alaris’ online account, where plant information can be entered or updated, and the result can be viewed and printed ready for use at the site.

Site analysis

Before Site Optimisation ‘went live’, Ørsted assessed Kodak Alaris’ operational and technical requirements, focusing on the consumption of gas and electricity, export potential, and the variable need for steam. Site visits also allowed Ørsted’s consultants to determine any operational constraints around particular assets, such as start-up periods and running times.

Daily schedules

Once operational, Site Optimisation calculated the optimal daily run schedules for Kodak Alaris against changing market prices, therefore reducing the time required to plan operations.

Ongoing support

The technical team at Ørsted was available via telephone or email to deal with any issues that Kodak Alaris encountered. Having met all key Ørsted team members in person during implementation, Kodak Alaris found it easy to make contact whenever the need arose.

The result

Through using Site Optimisation, Kodak Alaris has been able to take full advantage of the site’s flexibility capabilities and has followed Site Optimisation’s run schedules to within 3%. As well as boosting resource savings through a reduction in daily planning time, Kodak Alaris has optimised operational performance which has led to an 11% saving in energy costs.

“Now we enter plant information through our online account. It then analyses all of the information, and produces our optimum daily run schedule”, explains David Jeans, Energy Manager at Kodak Alaris.

“I’m able to take the information directly from the inter- face, print it out, and hand it to our operational staff in our morning production meeting. Everyone finds it really easy to use, as the solutions are always practical. It’s a very different plant from previously: we’d have a plan for the week that didn’t change all week because it was built on averages. Now we have a plan that changes from hour to hour, and that really optimises what the plant is doing each day.”

“I have weekly calls with our Account Manager at Ørsted, which helps us to keep an eye on things and make sure everything is developing in the right direction.”

“If anything unexpected happens, it’s reassuring to know that we also have access to technical support whenever we need it. We get to speak directly to the people who built the system, so they really know how it works and can work quickly to resolve any problems.

“From the word go, it’s been a collaborative experience and we’ve been able to establish great relationships with the technical support team at Ørsted, both in London and in Denmark. Their expertise complements ours, and they were extremely quick to understand the complexities of our site and what we were looking to achieve.

“I would definitely recommend Site Optimisation to other businesses which work similarly to ours. From a business perspective, the savings you achieve by using the solution make it a no-brainer.”

Through using Site Optimisation, Kodak Alaris has been able to take full advantage of the site’s flexibility capabilities and has followed Site Optimisation’s run schedules to within 3%. As well as boosting resource savings through a reduction in daily planning time, Kodak Alaris has optimised operational performance which has led to an 11% saving in energy costs.

When I heard about Site Optimisation at a seminar, it was a real ‘light-bulb’ moment. It’s unique – I’d never come across anything like it before, but it was the perfect fit for our needs.

David Jeans, Energy Manager, Kodak Alaris