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[Webinar Recap] Four Best Practices in Enterprise Optimization

ronchapek_2 Ron Chapek | Director of Product Management

Emerson Commercial & Residential Solutions

For large retailers with multi-site store networks, there are significant advantages to using alarm management services and enterprise software — from reducing operational costs and preserving food quality and safety to lowering maintenance costs and improving energy efficiency. In a recent E360 Webinar, Best Practices in Enterprise and Facility Optimization, I talked with Scott Fritz, Emerson’s director of enterprise services & IT operations, about the keys to maximizing performance in these critical areas. View the webinar in its entirety and continue reading to learn more.

The process of managing assets, food inventories, service requirements and energy efficiency at an enterprise level involves a variety of stakeholders, including store managers, service technicians, alarm technicians, facility managers, energy managers and food safety managers. Companies need both the proper tools and strategies to effectively coordinate these resources and manage their collective efforts.

The following four best practices are designed to leverage enterprise software and services to help your company achieve its critical business objectives.

  1. Gain a centralized view of operations. Today, multi-site retailers are tasked with managing large asset and equipment portfolios — such as aging HVAC, lighting and refrigeration systems — and an ever-increasing number of “smart” assets connected via the internet of things (IoT). Enterprise software offers a centralized view and management of these critical assets, enabling remote support, user access controls and network-wide broadcast of changes (such as refrigeration and HVAC setpoints and lighting schedules).

By optimizing facilities management and controlling setpoint data, large enterprises — such as a supermarket with 250 sites — can achieve up to $1M annually in operational labor savings.

  1. Establish effective alarm management. Keeping a network of sites and their assets performing optimally requires the abilities to mitigate costly failures, save energy, and ensure food safety. But with virtually thousands of issues to sort through at any given time, this is no small task. Alarm management services allow companies to filter out the noise of countless non-essential alarms and prioritize critical issues. These timely and pertinent notifications accelerate issue resolution and prevent their potentially negative consequences.

For example, by avoiding food loss and delaying the “shrink” of perishable items, companies can save more than $2M annually.

  1. Enable remote access. Service technicians and maintenance teams are running increasingly lean, with a scarcity of available new talent to replace an aging workforce. Enterprise software enables remote field connectivity to service issues via intuitive software that can be accessed on handheld computers and mobile devices. Having access to this data helps technicians evaluate and troubleshoot issues remotely — often eliminating the need for service calls (i.e., truck rolls) — while serving as a real-time training tool for new technicians.

The reduction of unnecessary truck rolls and service calls across an enterprise can save up to $1.5M annually.

  1. Automate setpoint and energy management. Facilities managers are under increasing pressure to meet myriad day-to-day commitments — all while trying to achieve their profitability targets and reduce their liabilities and risks. Enterprise software with predictive analytics capabilities can help automate the compliance of critical operating parameters — such as refrigeration and HVAC setpoints — and deliver insights that facilities managers can leverage to make informed decisions.

By deploying setpoint management tools that ensure continuous commissioning of equipment and establishing processes to maintain optimal energy levels, companies can achieve up to a $2.7M reduction in annual energy spend.

By following these four best practices, companies can transform the productivity, energy efficiency and overall optimization of their enterprise operations. Emerson has the enterprise software, alarm management services and domain expertise to help large supermarket and restaurant chains optimize their multi-site store networks. View this webinar in its entirely to learn more.

 

Integrated R-290 Cases Expand Into U.S. Markets

AndrePatenaude_Blog_Image Andre Patenaude | Director, Food Retail Marketing & Growth Strategy, Cold Chain

Emerson Commercial & Residential Solutions

I was recently asked to contribute to an Accelerate America article about the increasing use of R-290 in the U.S. commercial refrigeration market. The article featured a variety of perspectives from supermarket operators and equipment manufacturers. Read the full article (pg. 38) and more on Emerson’s perspective below.

Integrated R-290 Cases Expand Into U.S. Markets

A growing number of American retailers — including Target, ALDI US and Whole Foods Market — have been deploying self-contained, R-290 cases as spot merchandisers in hundreds of stores, many of which are mainly served by centralized rack systems. Some retailers regard these units as partial or even full-store alternatives to using a centralized rack-based system.

Obviously, this comes as no surprise to Emerson. Not only have we been partnering with R-290 equipment manufacturers for many years, we also support operators and commercial refrigeration designers alike in their efforts to utilize R-290 — and a variety of other lower-GWP and natural refrigerants — in their systems. As others have stated in the article, this trend reflects a shift in the research and development processes for some manufacturers, in that fewer emerging architectures are being designed to utilize hydrofluorocarbon (HFC) gases.

It’s further evidence that, regardless of the unpredictable state of environmental regulations, R-290 use in commercial refrigeration continues to gain traction. We at Emerson are seeing the use of integrated case architectures — where one or more R-290 compressors is/are housed within a refrigerated case — and the continued use of completely self-contained units as the most likely paths to wider adoption of integrated R-290 in 2019 and beyond.

While R-290 systems may have originally been born out of necessity to address environmental concerns, today they’re perceived in the market as much more than just eco-friendly alternatives. With the expansion of smaller-format stores and increasing retail urbanization, many times there simply isn’t enough space to accommodate a machine room for a traditional central system. In these scenarios, plug-and-play, low-charge, R-290 systems are an ideal fit.

The safe use of R-290, which is classified as an A3, highly flammable refrigerant, is governed globally by the International Electrotechnical Commission (IEC) and nationally by the Underwriters Laboratory (UL). Historically, these standards mandated that R-290 charge limits should be limited to a maximum of 150g. However, the IEC recently updated their standard (IEC 60335-2-89) to allow the use of up to 500g of A3s like R-290. This charge limit increase will enable more application flexibility for European food retailers.

It’s important to note that in the U.S., the UL standard still mandates a maximum of 150g charge limit for A3s. Even with the low charge limit of 150g, R-290 cases have proven viable options for many leading retailers in the U.S. market and abroad.

While the industry adapts to the charge limit increase, there are real-world installations that are also indicative of the safety and reliability of these self-contained, R-290 cases. Since 2013, an HEB grocery store in San Antonio has utilized the R-290 cases installed throughout the entire store as its primary refrigeration source. The designer of that architecture, who was also interviewed in the same article, stated that these cases have proved to be both safe and reliable — and have had no leaks since they’ve been installed.

Today we’re achieving more flexibility using R-290 systems with micro-distributed architectures utilizing integrated cases. They are designed to remove compressor exhaust heat via a shared glycol water loop that’s directed to the roof of the facility for heat removal. These systems typically stay within the 150g limit and enable a greater degree of scalability.

It will be interesting to see how the possibility of increasing the R-290 charge limit, as has been discussed and studied within the industry for years, might impact system design in the future. For now, R-290 seems to have a place — albeit a relatively niche one — in U.S. markets.

Transforming Data Into Maintenance Insights

ronchapek_2 Ron Chapek | Director of Product Marketing

Emerson Commercial & Residential Solutions

Today’s supermarket, restaurant and convenience store operators have an abundance of data at their fingertips. Most utilize facility management systems and controls to monitor refrigeration, HVAC, lighting and energy management. These platforms give them ability to respond to alarms that could impact customer comfort and food quality. But alarms are only the “tip of the iceberg” when it comes to this data’s potential usefulness. In a recent E360 article, we discussed how operators can transform this data into maintenance insights.

While many companies spend their time tracking, prioritizing and responding to alarms that need immediate attention, owners and operators have relatively limited visibility into overall operational status. But with deeper analytics of available data, operators can look “beneath the hood” of key systems and gain access to insights that could impact them in the future — insights that could potentially transform maintenance activities from a primarily reactive approach to a more condition-based, analytics-driven model.

The difference between “urgent” and “important”

One way to visualize the role of operational analytics in maintainance activities is by prioritizing maintenance events according to their urgency or importance. Maintenance events and operational decisions can be divided into four basic categories:

  • Don’t roll a truck (no action required)
  • Roll a truck soon (plan to take action)
  • Roll a truck now (take action now)
  • Take steps to improve (address at next scheduled maintenance)

Using the iceberg analogy, urgent issues represent events that you will need to respond to immediately — those that lie above the surface. Below the surface, you’ll find issues where analytics platforms can help operators make maintenance decisions based on their potential business impacts. Analytics can help identify issues that, while not urgent, are highly important — and may have otherwise gone unnoticed.

These insights often reveal areas of improvement that could either be addressed during scheduled service intervals or when the equipment or system condition indicates the need to address a potential issue. Armed with this knowledge, operators can receive advance notice of certain performance issues that may soon impact them.

Drive performance across the enterprise

The role of analytics within a maintenance framework can be extrapolated across an enterprise to maximize its potential. Drawing from a combination of equipment sensors and control system data, performance analytics can provide store operators and enterprise managers deeper insights for:

  • Real-time and historic operating conditions in their facilities and systems
  • Pressure, temperature and energy data to compare to established benchmarks
  • Enterprise- and store-level dashboards and prioritized notifications

For example, analytics allows for display case performance analysis based on temperature sensor data. Data may detect an anomaly in case temperature deviations that, while still within safe ranges, could indicate a larger performance issue. Instead of being notified with an urgent alarm, operators have advance notice to investigate issues at their discretion — and even preempt a potentially larger issue.

Enterprise operational dashboards can also be configured to display these insights and provide managers with visual snapshots of urgent and pending issues across their store networks — even enabling investigation into specific assets in their respective facilities.

If you’re ready to see what lies below the surface of your operational data and realize the true potential of analytics, contact Emerson to speak to one of our enterprise data analytics experts.

 

Advances Continue in Cold Chain Tracking Technologies

AmyChildress Amy Childress | Vice President of Marketing & Planning, Cargo Solutions

Emerson Commercial & Residential Solutions

This blog summarizes an article from Snack Food and Wholesale Bakery, “Advances in cold chain technology for snack and bakery warehousing and transport.” There have been significant technological advances in recent years to enable better temperature and condition monitoring, including key offerings from Emerson. Read the full article here.

In recent years, the Food and Drug Administration (FDA) has pressed for increased monitoring and documentation of refrigerator and freezer temperatures at every point along the cold chain to detect when cold storage temperatures fall out of the transported food’s safe range. Heightened awareness of foodborne illness as a serious health problem has driven advanced monitoring systems that trigger alarms and notify personnel should temperature conditions deteriorate.

However, these advanced systems are largely the domain of processing plants, warehouses and supermarkets, fixed locations where continuous monitoring and wireless data collection and processing are incorporated into an IT infrastructure — but they’re quickly earning industry-wide adoption.

When a food shipment is transferred to a truck, train or ship, accessing and documenting its temperature data becomes problematic and limited. Historically, food transport has been the weakest link in cold chain tracking. That’s why it’s become increasingly important to track temperature data on frozen and refrigerated food in transit to ensure food security and provide operators with end-to-end documentation.

This is where the latest advances in cold chain technology come in: the development of monitoring systems that include data loggers, i.e., electronic devices that communicate with sensors to collect data over time. When fully automated, they can eliminate the errors of manual tracking and recording information during transit, transmitting and storing continuous temperature data in real time.

Emerson Cargo Solutions is one of several companies working to fill data gaps during transit, with a suite of cellular monitors and loggers — GO Real-Time Trackers — which track and log the status of perishable products shipped across the entire cold chain, all in real time. Using cellular technology and the processing capabilities of the IoT, GO Real-Time Trackers can continuously transmit and log temperature and location data and send alerts from the loading dock to the shelf.

GO Real-Time Trackers are affordable, easy to use, and small enough to fit in the palm of one’s hand, making them particularly functional for tracking and logging goods in transit. Yet they also provide global visibility to shipments while transmitting temperature data to end users’ systems via the cloud and the IoT.

To use a GO Real-Time Tracker, a worker simply pulls a tab to start the device, places it in a container or trailer, and inputs its serial number into Emerson’s Oversight Exchange Data Integration app. From there, end users have access to comprehensive and automated monitoring. Logging data is encrypted for security and transmitted cellularly to the cloud and IoT for real-time processing and analysis. With either a smartphone or tablet, a user can check shipment status and generate documentation on the go. And the real-time data and documentation that GO Real-Time Trackers are capable of collecting are extensive:

  • Maps, graphs and charts of shipments with location and temperature details
  • Shipment summary reports using GO Real-Time Tracker serial numbers
  • Current product temperatures, temperature ranges and mean kinetic temperatures
  • Trip name, current trip status, location and duration
  • Total time out of cell range, above range and below range
  • Temperature graphs
  • Alarm events

End-to-end, real-time cold chain temperature monitoring and logging with GO Real-Time Trackers provide a higher level of overall security. Users can identify and fix previously unknown problem points in the cold chain. IoT connectivity and cellular communication make it possible for apps to monitor temperatures at set parameters throughout transport. And GO Real-Time Tracker documentation provides transparency, generating comprehensive reporting to comply with regulatory agency requirements for food safety.

Bringing the Need for Qualified Technicians Into Focus on National STEM Day

benpicker Ben Picker | Product Manager – Copeland Condensing Units

Emerson Commercial & Residential Solutions

National STEM Day is Nov. 8. From Emerson’s perspective, it’s a day to recognize the importance of science, technology, engineering and math — not only in our education curriculum, but also in the heating, ventilation, air conditioning and refrigeration (HVACR) industries.

Bringing the Need for Qualified Technicians Into Focus on National STEM Day

Bringing the Need for Qualified Technicians Into Focus on National STEM Day

With the commercial refrigeration industry evolving to utilize more sophisticated technologies, technician jobs are becoming more technological than mechanical — and becoming viable options for those pursuing a STEM career path. A new workforce recruitment initiative by the Heating, Air-conditioning and Refrigeration Distributors International (HARDI) is addressing the technician shortage head-on via a new full-length documentary.

HVACR supply chain feeling the impacts

The impacts of the service technician shortage are being felt throughout the HVACR supply chain. While the vast majority of HVACR contracting business owners today are actively looking for technicians, this pain has far-reaching consequences — from wholesaler distributors to end users, owners and operators. Whether you’re operating a supermarket, c-store, restaurant or virtually any facility that has HVACR needs, the lack of qualified technicians is making it increasingly difficult to find reliable sources for new installations, routine servicing or emergency repairs.

And while industry stakeholders have been sounding the alarms for nearly a decade, it’s a problem that’s not going away. According to the U.S. Bureau of Labor Statistics, HVACR mechanic and installer jobs are expected to grow at a rate of 15 percent nationwide through 2026.

A perfect storm of market trends, technological advancements and demographic changes are compounding the issue. This is especially true in refrigeration, where shifting store formats and environmental regulations have led to a proliferation of system types. These systems are introducing connected technologies, electronics and alternative refrigerants, many of which represent completely new servicing procedures. As the industry struggles to attract a new generation of recruits, many of our current service technicians are scrambling to keep pace with these system changes, or are planning for retirement.

HARDI releases “Hot Commodity”

The goal of HARDI’s new workforce recruitment initiative is to spread awareness of the HVACR wholesale distribution industry to the younger generation and encourage these individuals to pursue an HVACR career path. To spearhead this effort, HARDI is releasing a documentary that exemplifies their mission and explores the many HVACR-related career opportunities.

While the full-length film has yet to be released, HARDI is currently promoting a short trailer of the documentary. As one of the professionals featured in the film states, now’s the time “for the younger generation to carry the ball” forward.

The themes presented in the documentary include:

  • Alternative to traditional college — Many high school students are encouraged to attend college, even if it’s not necessarily the best fit. Vocational and technical schools offer an alternative to traditional college, while allowing attendees to begin earning a living as they learn.
  • Financial viability — With a median annual salary of $47,080, HVACR technician profession earnings are significantly higher than other occupations, even though the job doesn’t require a four-year degree. As one of the contractors in the film explained, it’s possible for service technicians with 10 years of experience to earn as much $100K per year. Increased demand for these jobs is driving salaries upward.
  • Variety of career paths — Whether you’re coming out of high school, or college, or seeking a career change, there are multiple opportunities and positions to explore. For example, the film mentions a microbiologist who sought a career change offering the potential to achieve ideal indoor air quality.
  • Changing perceptions — The perception of working in a dirty, dark and dangerous environment is changing. The next generation of HVACR technicians will work with rapidly changing, emerging technologies, electronics, computers and more.
  • Evergreen market — Achieving ideal air quality and reliable refrigeration in a dynamic market is an evergreen opportunity. As a result, HVACR professions are among the most sustainable across all occupations.

 

As a HARDI supporter and long-time champion of this cause, Emerson will continue to do its part to raise awareness of the technician shortage facing our industry. Our Educational Services group frequently partners with vocational and technical schools to donate equipment, offer training and career advice, and even judge HVACR-related competitions. Look for the full HARDI documentary to be released later this year.

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