J.R. Simplot has completed a 400,000 square foot expansion of its potato processing facility in Portage la Prairie, Manitoba, more than doubling capacity at the location. The enlargement further solidifies the Boise, Idaho, USA-headquartered global food and agriculture company’s footprint in Canada and the Midwest, allowing it to diversify distribution channels to eastern North America and beyond.
The project incorporated energy efficiency improvements into the design and operations in partnership with Efficiency Manitoba. The collaboration delivered significant energy and bill savings and established the plant as one of the most energy-efficient facilities of its kind in the world.
Simplot’s facility buildup included designing and implementing several energy efficiency enhancements, maximizing the energy efficiency of its production and operations, as well as constructing a more energy-efficient structure itself.
Participation in Efficiency Manitoba’s Custom Energy Solutions Program and New Buildings Program enabled the energy efficiency enhancements. The government-owned crown corporation provided Simplot with technical support throughout the duration of the project and worked alongside consultants and other efficiency professionals to ensure energy-efficient measures were incorporated.
Simplot and Efficiency Manitoba partnered on multiple processing-related energy efficiency opportunities. The most significant electricity-saving upgrades included installing variable speed drives on 12 fans and 37 pumps, yielding over 9 gigawatt-hours (GWh) of annual electricity savings, with another 8.8 GWh of savings derived from more energy-efficient refrigeration systems. The installation of a heat recovery system, consisting of a series of heat exchanges which remove heat from the fryer exhaust to preheat process hot water and incoming fresh air through the building’s HVAC system, produces over 34% of Simplot’s natural gas savings.
Other key energy-saving features of the expansion include improved HVAC, building envelope, and lighting systems. Through the support of Efficiency Manitoba’s New Buildings Program, Simplot’s final energy model confirmed their expansion exceeded the minimum energy efficiency requirements of the Manitoba Energy Code for Buildings by 14.5%. This reduces the building’s operating costs by $270,000 annually.
Natural gas savings are expected to provide annual greenhouse gas emission reductions of over 11,000 metric tons of carbon dioxide equivalent. So not only will Simplot realize impressive energy and bill savings, but the company will also reduce its environmental impact.
“We appreciate the incentives available for energy efficiency projects, which enable us to justify projects that otherwise may not have been implemented,” said Simplot Energy Engineer Don Strickler. “We are very proud of our efforts to continue to minimize our environmental footprint and optimize water and energy usage.”
“Simplot has been an outstanding corporate and community partner since establishing its operations in Manitoba,” said Manitoba Minister of Agriculture Ralph Eichler. “This investment further cements their reputation as a pillar in Manitoba’s agriculture and food processing sector. The plant’s increase in capacity also presents a tremendous opportunity for farmers to strengthen their partnership with a reliable local processor and increase potato production in Manitoba.”
Situated 50 miles west of Winnipeg in south-central Manitoba, Simplot’s Portage la Prairie potato processing facility has access to potatoes and a reliable the workforce, as well as growing capacity needed to meet production increased market demands.
When Simplot began operations in Portage in 2003, the plant was designed to be enlarged to match future requirements. Since then market demand, both domestically and internationally, necessitated expansion of the facility from 180,000 to 460,000 square feet – more than doubling the company’s need for potatoes from regional growers while increasing employment to more than 300.
In addition operating potato and other food processing factories in Canada and the United States, the family-owned and privately held company’s integrated portfolio includes major operations in Mexico, Argentina, Australia, and China. Its wide range of frozen products runs the gamut from french fries and other value-added potato specialties to berries and other fruit, vegetables, avocado pulp, halves and guacamole.
