Business and Industrial Case Studies

Industrial
Case Studies
Toronto Hydro

Tyco Safety Products manufactures leading edge Digital Security Controls
(DSC) branded electronic intrusion alarm products in its 188,000 square foot
facility on Bridgeland Avenue. This is a true Canadian success story with over
700 employees manufacturing sophisticated systems that are shipped to over
140 countries.
Glen Brislan, Vice-President, Supply Chain praises his workforce for their
ability to continually improve the quality of their products, squeeze out costs,
meet stringent on-time delivery dates and be flexible to meet the manufacturing
requirements to deliver over 500 different products from one location.
“We are very competitive in a global manufacturing environment,” says Brislan.
“And we look to every opportunity to find efficiencies, and that includes our
physical plant. That’s why Toronto Hydro’s RETROFIT PROGRAM made so
much sense for us.”
above: Glen Brislan and Rexford Yirenkyi
top right: Glen Brislan
saveONenergyOM
FOR BUSINESS
Tyco Safety Products
project statistics
188,000 sq. ft. manufacturing
and shipping facility for security
products
Before: 804 T-12 fluorescents and
92 360W high metallic fixtures
with inefficient ballasts
After: 804 T-8 fluorescents and
92 200W metal halide fixtures with
high efficiency ballasts
and reflectors
Project cost: $216,717
Simple payback after incentive:
Approx. 1.8 years
Return on investment (ROI):
Approx. 46.1%
Electricity savings:
66% of lighting consumption
Case Study
February 2012
Shine a light on savings: Tyco retrofit
delivers ROI of 46% with 1.8 year payback

“It took Toronto Hydro less than
two weeks to approve our project.”
Rexford Yirenkyi, Maintenance and
Facilities Manager, was given the task
to look into the Toronto Hydro
RETROFIT PROGRAM. Yirenkyi is no
stranger to these types of efficiency
initiatives. “We already have occupancy
sensors in meeting rooms and
washrooms, we’re very efficient at
recycling and we’ve eliminated a lot of
cardboard by using recyclable totes.
So I was keen to explore the
RETROFIT PROGRAM.”
After defining the scope of the project
with Ed Alexander of Progressive
Lighting, Energy & Design who designed
the lighting retrofit and supplied
materials, Yirenkyi submitted a
RETROFIT PROGRAM application to
Toronto Hydro. In under two weeks, the
project was approved. Implementation
(by Gemini Group Electrical Systems
Inc.) took eight weeks with minimal
disruption. Within a week of job
completion, Toronto Hydro was back
to inspect the project and provide final
sign-off for the incentive.
Excellent employee feedback
For Tyco, an added bonus was the
spontaneous and positive feedback
from employees. Says Brislan, “We
knew they would notice the difference
in brightness and we were very happy
to hear all of their comments. We have
a good relationship with employees
here, and this added to it. The new
lighting is good for everyone.” The old
fluorescent T-12 system provided 37
foot candles of light, while the new T-8
fluorescent system delivers 54 foot
candles. That’s nearly 46 per cent
brighter in most areas.
The CO2 reduction story in trees
and cars
To really bring home the environmental
benefits of this project, Tyco’s
contractor noted that the net effect of
this project reduces CO2 emissions
from electricity generation by 137.48
tons. That is the equivalent of planting
30 full size trees or taking 30 cars off
the road in one year.
More energy saving programs on
the way – peaksaver®
is next
Tyco is now looking for further
opportunities to save. Next to be
implemented is peaksaver®
on the 20
roof-top air conditioners. Says Yirenkyi,
“While we appreciate the credit we’ll get
on our bill, peaksaver is more about
being a good corporate citizen and
helping the environment.”
“We are proud that we are good corporate
citizens. We value the many environmental
benefits that the RETROFIT PROGRAM delivers.”
Rexford Yirenkyi, Maintenance and Facilities Manager
Visit torontohydro.com/business
for more information or to apply online for saveONenergy programs.
Or contact us today at: Tel: 416.542.3388 Fax: 416.542.2980 Email: cdm@torontohydro.com
Subject to additional terms and conditions found at torontohydro.com/business. Subject to change without notice. Funded by the
Ontario Power Authority and offered by Toronto Hydro. This business participated in the Business Incentive Program (BIP) offered
through Toronto Hydro and funded by the Ontario Power Authority. A mark of the Province of Ontario protected under Canadian
trade-mark law. Used under sublicence. OM
Official Mark of the Ontario Power Authority. Used under licence. The star design is a
trade-mark of Toronto Hydro Corporation used under licence.’Toronto Hydro’ means Toronto Hydro-Electric System Limited.
Toronto Hydro
Incentive Programs
Toronto Hydro offers
saveONenergy programs that
provide financial incentives and
technical assistance to help
improve your energy efficiency.
With programs available for
commercial, institutional,
multi-residential and industrial
buildings, conservation can be
an attractive investment
opportunity with excellent
returns. Discover your best
energy-saving opportunities by
starting with an energy audit
and then apply for the
appropriate incentive programs
for further funding.

ShawCor is a global energy services company that focuses on technology-
based products and services for markets including petrochemical, electrical
utility, communications, automotive and electronics.
The company was formed in the 1930s in south-west Ontario, and now has
over 5,800 employees in over 20 countries.
On Bethridge Road in Toronto, ShawCor has two divisions known as DSG-
Canusa and ShawFlex, which occupy approximately 230,000 square feet.
Here they manufacture heat-shrink products such as rubber tubing and
sleeves, along with cables used for instrumentation and robotics.
For this project, the company identified two immediate opportunities for
electricity savings: replacement of nine heaters that are used in creating end
caps on rubber tubing and overall lighting in key areas of the plant.
Toronto Hydro worked closely with the ShawCor team including Morteza
Hashemian, Process Engineering Supervisor; Lou Bacs, HSE Engineer and
Robert Fuller, Plant Engineering Manager.
saveONenergyOM
FOR BUSINESS
ShawCor Ltd –
DSG-Canusa
project statistics
3 end cap machines, each using 3
electric heaters running 24/5
Before: 8 kW / heater = 72 kW
After: 0.5 kW / heater = 4.5 kW
Approx. 1.05 years
Approx. 95%
Electricity savings: 67.5 kW
ShawCor Ltd – ShawFlex
project statistics
Lighting for over 150,000 sq. ft.
of manufacturing
Before: 162 400-Watt metal
halide fixtures
After: 162 6-lamp fluorescent T-8
light fixtures
Approx. 1.39 years
Approx. 77.8%
Electricity savings: 45.9 kW
Case Study
February 2012
ShawCor sees big savings and fast
ROI in equipment and lighting retrofits
above: Morteza Hashemian, P.Eng.

“We knew that our equipment
was a prime candidate for
electrical savings.”
“In our manufacturing process, we use
heaters to pinch and seal rubber
tubing to create end caps. We have
three machines, each with three
heaters. They are always on and we
knew they represented an opportunity
for savings,” said Lou Bacs.
Morteza Hashemian and his team, in
coordination with Bacs, replaced the
nine electric resistance heaters with
infrared heaters, bringing down peak
demand from 72 kW to 4.5 kW, a
reduction of 93.7%.
New lighting reduces the plant’s
heat load
In the ShawFlex factory, ShawCor had
been using 162 400-watt metal halide
fixtures. Bacs and Robert Fuller
realized there was a potential for
savings by upgrading.
“Working with our contractors, we were
able to replace the metal halide fixtures
with 162 6-lamp fluorescent T-8 light
fixtures,” said Fuller. “In addition to the
reduced electrical use, the new lighting
is brighter and significantly reduces the
heat load.”
Both kilowatt and kilowatt-hour savings
were substantial. The kilowatts were
reduced from 74.2 kW to 28.3 kW, a
savings of 45.9 kW, while kilowatt-
hours were reduced by 392,808.
The Retrofit Program works
hand-in-hand with ShawCor’s
Code of Conduct
ShawCor’s Code of Conduct commits
them to conducting business in a
manner that protects the environment,
reduces waste and conserves resources.
By lowering electricity requirements,
ShawCor helps reduce generation
demand and lower peaks, both of
which have positive impacts on
our environment.
Toronto Hydro was knowledgeable,
helpful and quick to respond
The key to success of both the lighting
retrofit and equipment replacement
initiatives was an efficient working
relationship with Toronto Hydro.
Bacs appreciated the responsiveness
and help from the team at Toronto
Hydro. “We worked mainly with Bill
Scott. He helped us define our
opportunities and made the whole
process easy. We’re now looking at
further ways to take advantage of the
Retrofit Program.”
“We have equipment running 24/5. The
Retrofit Program was further incentive for
us to make it as energy efficient as possible.”
Lou Bacs, P.Eng., HSE Engineer
Subject to additional terms and conditions found at torontohydro.com/business. Subject to change without notice. Funded by the
Ontario Power Authority and offered by Toronto Hydro. This business participated in the Business Incentive Program (BIP) offered
through Toronto Hydro and funded by the Ontario Power Authority. A mark of the Province of Ontario protected under Canadian
Official Mark of the Ontario Power Authority. Used under licence. The star design is a
trade-mark of Toronto Hydro Corporation used under licence.’Toronto Hydro’ means Toronto Hydro-Electric System Limited.
Toronto Hydro
Incentive Programs

With approximately 1,200 of Ontario’s dairy farmers counting on them to turn
milk into a variety of dairy products, Gay Lea Foods Co-operative puts a
priority on keeping production lines running. So when it came to improving
energy efficiency, maintaining production integrity was of vital importance.
Through the assistance of suppliers and Toronto Hydro, equipment and
lighting retrofits at Gay Lea’s Toronto area plants prove that implementing
energy efficiencies doesn’t have to impact production. Gay Lea participated
in the Business Incentive Program (BIP) funded by the Ontario Power Authority.
Similar incentives can be found through saveONenergy incentive programs.
saveONenergyOM
FOR BUSINESS
GayLeaFoodsCo-operative
project statistics
Lighting retrofit at two
processing plants
Before: 377 metal halide and T-12
fluorescent fixtures
After: 434 lower wattage T-5 and
T-8 compact fluorescent fixtures
with occupancy sensors
Approx. 2.2 years
Approx. 46%
Annual electricity savings:
Approx. $33,924
Replacement of fixed speed air
compressor with variable speed
drive air compressor
Before: 100 hp fixed speed air
compressor consuming 13,000
kWh/week
After: 100 hp variable speed air
compressor consuming 8,000
kWh/week
Approx. 2.2 years
Approx. 45%
Annual electricity savings:
Approx. $26,000
Case Study
February 2012
With energy-efficient retrofits, Gay Lea Foods
whips up sustainable energy savings
above, left to right:
Rahul Nakra, Corporate Process Engineer, Zbigniew Ewertowski, Director of Corporate Engineering

Knowledge helps yield power savings
An energy audit is the first step for any
business looking to save energy. In
Gay Lea’s case, audits revealed that
upgrading lighting and replacing aging
air compressors provided the best
opportunity for realizing energy
efficiencies. And, as Toronto Hydro’s
Bill Scott pointed out, both were
eligible for incentive programs offered
through Toronto Hydro.
Matching capacity to demand
Through computer analysis, two 100 hp
fixed speed air compressors were
found to be providing more capacity
than was currently needed, thereby
wasting energy. Replacing one
20-year-old compressor with a newer,
more efficient variable speed drive unit
allowed Gay Lea to more accurately
match capacity with demand. “Any
industrial facility should be looking at
variable speed drive where demand
varies to help eliminate energy waste,”
reports Gay Lea’s Director of Corporate
Engineering, Zbigniew Ewertowski.
Improving lighting quality while
saving energy
In a food processing facility, lighting
must meet the Canadian Food
Inspection Agency standards. Replacing
older, less efficient metal halide and
T-12 fixtures with energy-efficient T-5
and T-8 technology resulted in
reductions in wattage while improving
lighting quality. Since the newer
fixtures also produce less heat, they
can also lower the load on HVAC systems.
Maintaining production integrity
Both projects proceeded with minimal
disruption to daily production as a
result of a concerted effort by all
stakeholders – equipment suppliers,
Toronto Hydro and Gay Lea and its
employees. As Rahul Nakra, Corporate
Process Engineer at Gay Lea, points
out, “Our employees really got behind
these initiatives. They knew that saving
energy whenever we can is simply the
right thing to do.”
Encouraged by their success, Gay Lea
is pushing ahead for greater energy
savings. Lighting retrofits are nearing
completion at other plants and as
aging equipment needs replacing,
energy efficient equipment tops the list.
“Proven results and a positive experience
encouraged us to apply what we learned
through these projects to our other facilities
for additional energy savings.”
Zbigniew Ewertowski, Director of Corporate Engineering
Subject to additional terms and conditions found at torontohydro.com/business. Subject to change without notice. Funded by the Ontario
Power Authority and offered by Toronto Hydro. This business participated in the Business Incentive Program (BIP) offered through Toronto
Hydro and funded by the Ontario Power Authority. Project results have been verified by Toronto Hydro. A mark of the Province of Ontario
protected under Canadian trade-mark law. Used under sublicence. OM
Official Mark of the Ontario Power Authority. Used under licence. The
star design is a trade-mark of Toronto Hydro Corporation used under licence.’Toronto Hydro’ means Toronto Hydro-Electric System Limited.
Toronto Hydro
Incentive Programs

KIK Custom Products manufactures and packages household products such
as sunscreens and toothpaste for many leading brands. Compressors are used
throughout the facility to fill bottles and cap them.
Upon an analysis of their systems, KIK found that the fastest way to cut
electricity use for their compressors was to replace five old units with two
energy-efficient models. This qualified for a RETROFIT PROGRAM incentive
which resulted in an impressive payback of mere months. The entire project,
from proposal to commissioning, was completed in just six months.
“Compressors are at the heart of the operation here. They run 24/7. Every
line has equipment which is driven by compressed air. Before the project,
compressors consumed about 20 per cent of overall electricity. Now it’s down
to 10 per cent. We’ll see those savings compounded year after year.”
saveONenergyOM
FOR BUSINESS
KIK Custom Products
PROJECT STATISTICS
By replacing 5 inefficient
compressors with 2 energy-
efficient units, KIK Custom
Products cut annual electrical
costs by over $180,000. The
incentive reduced the project
cost to $83,245, which created
a payback of just 6.4 months.
Total project cost: $191,370
Demand savings: 194.4 kW
Energy savings:
1,700,000 kWh/yr
Electricity savings:
Over $180,000/yr
Incentive: $95,685
Case Study
March 2014
right:
Kamen Petrov, Engineering Manager,
KIK Custom Products
A 6.4-month payback —
that’s big savings out of thin air

What is compressed air costing you?
Ontario manufacturers spend up to
20 per cent of their electricity bills on
typically use 20 to 50 per cent more
electricity than necessary. Start
leaks, implementing equipment
such as zero loss drains and then
compressors themselves. The
payoff is often immediate.
Many operators have never monitored
the energy use of their compressed air
system, and therefore don’t know the
true costs. This table outlines the typical
per motor consumption costs based on
hours of operation (assumes $0.10/kWh).
The right savings solution
isn’t always obvious
Call Toronto Hydro to discuss your
system. You may qualify for incentives
for an energy audit or engineering study
offer up to 100 per cent funding* to hire
an expert to conduct a system audit.
“Take advantage of the incentives.”
Petrov’s advice for other businesses:
“Anybody looking at these projects will
prices go up. It would be simply foolish
not to take advantage of them.”
“In addition to the direct cost savings from
energy consumption, we also beneﬁted from
cost avoidance, not having to deal with repair
and maintenance for the next 5 to 10 years.”
Kamen Petrov, Engineering Manager, KIK Custom Products
for more information or to apply online for incentive programs.
Hotline: 416.542.3388 Fax: 416.542.2980 email: cdm@torontohydro.com
*Incentives are subject to maximum amounts based on the potential saving and the applicable incentive program. Subject to additional
terms and conditions found at torontohydro.com/business. Subject to change without notice. Programs are funded by the
exclude taxes. OM ®
A registered trademark of Toronto Hydro Corporation.
Used under licence. ‘Toronto Hydro’ means Toronto Hydro-Electric System Limited.
Toronto Hydro
Incentive Programs
buildings, conservation can be an
attractive investment opportunity
with excellent returns. Discover
your best energy-saving
opportunities by starting with an
energy audit and then apply for
the appropriate incentive
programs for further funding.
Compressor
size
1 Shift
(2,250 hrs)
2 Shifts
(4,250 hrs)
3 Shifts
(8,400 hrs)
10 HP $1,720 $3,250 $6,430
25 HP $4,300 $8,130 $16,060
100 HP $17,120 $32,330 $63,900
Based on $0.10/kWh

Plastics manufacturer maintains operations
while reducing energy usage and costs
The Big Picture
ORBIS Corporation is a part of Menasha Corporation, an innovative manufacturing
company with over 160 years of history. ORBIS provides reusable plastic containers
and other packaging systems to customers all over the world. With 10 locations in
the US and Canada, their manufacturing plant in Toronto uses multiple presses,
a grinder and an extruder to produce thousands of plastic products a year.
ORBIS Corporation strives to make a positive difference in communities in which it
operates and it is committed to improving the environment. In 2010, ORBIS
launched its first Annual Sustainability Report to ensure they provide solutions that
both create economic value and are as friendly to the environment as possible.
saveONenergyOM
DEMAND RESPONSE
ORBIS Corporation
Industry: Plastics Manufacturing
Location: Toronto, Ontario
DR Program:
saveonenergy DEMAND
RESPONSE DR3 (DR3)
DR Strategy: Curtailment
Primary Curtailment Strategy:
Temporary shutdown of grinder
and extruder
Annual Payments:
Approximately $10,700 per year
CASE STUDY
January 2014
RIGHT:
ORBIS Corporation, Toronto Facility
ORBIS Corporation breaks the mold
with DR3 in Toronto

Reducing Costs
In April 2010, ORBIS worked with
Toronto Hydro and EnerNOC to
participate in the saveonenergy
DEMAND RESPONSE DR3 program.
ORBIS was determined to reduce its
energy demand and cut costs.
While the financial and environmental
benefits were enticing, ORBIS
conducted a close evaluation of the
impact of demand response on its
business. At first, ORBIS leaders did
not like the idea of shutting down any
manufacturing equipment. “Our
operations run 24 hours, 7 days a
week, every day of the year. We can’t
stop production, even if it is for a
couple of hours,” said David Berg,
Maintenance Manager at the Toronto
facility. However, when they learned
that Toronto Hydro and EnerNOC
would work with them to design a
customized plan that would minimize
disruption to the business, they
became comfortable with a curtailment
strategy that works well with their
operations. During a dispatch, ORBIS
shuts down some of the machines that
are not process-critical, like the grinder
and the extruder. They also pay close
attention to the weather and decide if
they can adjust any other non essential
load, like air conditioning or lighting.
Depending on the orders they
have that day, they can even shut
down some of the molding machines.
Planning Ahead
Since joining the program in
2010, ORBIS has been dispatched
an average of six times per year.
Dispatches in Toronto tend to occur
during the summer months, when
peak demand is high. “Planning for
a dispatch is easy. EnerNOC notifies
me in advance, and I inform plant
workers. We adjust our operations
accordingly, and everyone knows
we are participating in demand
response,” said Berg.
As part of its participation in
DR3, ORBIS received EnerNOC’s
powerful online energy profiling
software that gives Berg access to
real time energy data. Using this tool,
he can decide which machines to
shut down in order to reduce demand
to the desired load.
The Future
Participating in demand response is
helping ORBIS achieve its sustainability
goals, and helps Toronto Hydro fulfill
its commitment to energy conservation.
As part of Menasha Corporation,
leaders at ORBIS are clearly focused
on respecting and protecting the
environment for today and for
generations to come. “Sustainability is
a big part of what we do,” added Berg.
The energy curtailment plan is an
integral part of ORBIS’s strategy to
reach a 20% absolute reduction in
carbon emissions target by 2020.
“We were looking for ways to reduce our electricity
cost. With demand response, we offset our peak,
and we get paid to do it. It’s that simple.”
David Berg, Maintenance Manager
torontohydro.com/demandresponse
Hotline: 416.542.3388 Fax: 416.542.2980 email: cdm@torontohydro.com
Subject to additional terms and conditions found at torontohydro.com/demandresponse. Subject to change without notice.
Funded by the Ontario Power Authority and offered by Toronto Hydro. A mark of the Province of Ontario protected under Canadian
Official Mark of the Ontario Power Authority. Used under licence. ®
A registered trademark
of Toronto Hydro Corporation used under licence. “Toronto Hydro” means Toronto Hydro-Electric System Limited.
Shed Load. Get Paid.
Earn payments for reducing
electricity use on demand.
There are many ways to
participate in DR3, including:
• Powering down non-critical
equipment and lighting
• Shifting production to an
off-peak period
• Generating your own power

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Business and Industrial Case Studies