A Touch of Alchemy Transforms a Vermont Brewery

“When people walk in the door, their jaws drop,” said John Kimmich, co-owner and head brewer at The Alchemist Brewery. “The natural light, the energy efficiency of the building — it’s a church to beer.”

The original Alchemist location opened in Waterbury, Vermont, in 2003. After eight years of success, co-owners John and Jen Kimmich decided to open a second location in Stowe, Vermont, to help meet their growing production needs. The second location of The Alchemist Brewery was built with a vision of breaking from fluorescent-lit monotony, to create a beautiful, inviting space for beer enthusiasts to come together, relax and enjoy the brewery’s nationally respected Heady Topper IPA.

When Kimmich set out to build the brewery’s Stowe facility, he was determined to create a space that was as efficient as it was alluring. “We wanted to make use of the natural light, while considering the environmental responsibility of the brewery,” he said. Kimmich recognized the impact of the beer brewing process itself, and the number of wash-down and boiling procedures involved. The brewing process often creates a humid environment, so humidity control was billed as a top priority as construction on the second Alchemist facility began to take shape.

It was critical to control humidity for the space, and keep the process equipment and floors as dry as possible, to avoid the possibility of patrons slipping and falling in the tasting room. Of course, creating a comfortable environment was also top of mind, with the brewery hoping to maintain a 74-degree Fahrenheit indoor temperature and proper ventilation in the open floor plan. 

The town also had odor control and waste handling requirements for the brewery to abide by, which influenced the construction plans. “We wanted to keep our environmental responsibility in mind, to create the kind of place where you want to be, from everyone’s point of view,” said Kimmich.

The brewery’s construction manager brought the VHV Company in as their design/build contractor based on the company’s knowledge of the brewery process and experience with brewery applications. With a trusted relationship that spans more than 17 years, VHV contacted Trane to discuss project challenges and the best mix of heating ventilation and air conditioning (HVAC) equipment and controls to support the operation.

Improving efficiency

An 80-ton high-efficiency air-cooled Trane® CGAM scroll chiller was selected to meet the facility’s needs. Featuring onboard pumps with variable frequency drive, the chiller reduces energy use and creates a comfortable environment for employees and visitors. With a limited building footprint, the chiller was installed outside to allow for more useable interior space for the brewery equipment and operation. Staying cognizant of the owner’s environmental concerns, a free cooling unit was also installed, allowing the scroll chiller to remain idle when low outdoor temperatures enable the free cooler to take on the full load. This greatly reduces energy use and helps meet sustainability requirements.

Enhancing comfort and air quality

Twenty-four feet above the production floor, the VHV team installed a Trane Performance Climate Changer™ air handler with a CDQ™ (Cool, Dry, Quiet) wheel to handle dehumidification and space cooling demands. Rather than lifting the entire air handler to put it in place, the modular unit was raised to the platform in eight sections where it was easily assembled.

After cooling and initial moisture removal via the cooling coil, supply air flows through the CDQ desiccant wheel, which attracts and holds water vapor from the saturated air. The wheel rotates slowly into the upper air path where moisture is released into the lower relative humidity airstream. The moisture is then removed through the cooling coil, and the process repeats.

With the wheel in series with the airflow, the CDQ system improves the dehumidification capacity of standard cooling equipment from 20 to 300 percent, enabling a 5- to 15-degree lower dew point. The CDQ system limits the amount of outdoor air required, eliminating the need for expensive charcoal filters to control odors. The system easily helps to resolve The Alchemist’s humidity concerns, while keeping costs low.

Controlling system operations and energy use

Well-suited to enable desired sequencing and effective equipment interface, a Trane Tracer™ SC building automation system (BAS) was installed to maintain space conditions. With the web-based Tracer SC, facility staff at the brewery can access systems remotely from their smartphone or tablet to ensure temperature and humidity levels are as desired, check airflow rates, adjust setpoints, troubleshoot issues or conduct daily tasks.

“It is really cool to be able to monitor the building and turn things down at night,” said Kimmich. “We don’t have to worry that things run and run and run just because we forgot to go in that room and check it that night. You can log in to your computer and see everything you need to, and make adjustments right there.”  

Easy-to-use custom graphics on the Tracer SC provide a pictorial representation of the building systems. With a click of the mouse, brewery staff use the intuitive system to complete a building check, make overrides, change screens from one floor plan to another and interface with specific pieces of equipment. They can also choose to look at data logs and trends to monitor system performance over time.

To accommodate the expansive floor plan, a Trane Air-Fi™ wireless system was used to connect the system controllers, unit controllers, air handlers, VAV boxes, fan coils and zone sensors, eliminating the time and expense of running conduit wire, and preserving building aesthetics.

Results

Working together, VHV and Trane delivered a complete design/build equipment and controls solution for The Alchemist Brewery’s Stowe facility, meeting the owners’ specific humidity, comfort and efficiency requirements. “Working with VHV and Trane enabled us to do this project in a way that suited our needs and timelines,” said Kimmich. “The result is a new facility that lives up to our standards, the high standards that have gotten us to where we are today.” With the facility’s environment taken care of, Kimmich and his team can get back to what they’re best at — “Turning matter into gold, that’s what we do.”

By Al Fullerton, Systems Leader, Trane

To maximize efficiency of the entire building It’s important to first consider how to make the entire system more efficient before going granular and looking at individual pieces of equipment.

In commercial building design, individual pieces of heating, ventilation and air conditioning (HVAC) equipment are often selected based on their efficiency. It’s natural to want to choose the most effective solution, and many times we consider this through the performance of an individual component.

But is this really the best way to achieve the most efficient building performance?

It may seem counterintuitive, but the most efficient piece of equipment may not always result in the most efficient building or system performance. There are many variables that contribute to optimized building performance. It depends on how the building is being used and occupied, how the various pieces of equipment in the building interact and work together, and what the goals are for the facility.

This makes it important to look beyond the efficiency of a single piece of equipment and instead consider building performance and efficiency — seeing the whole as greater than the sum of its parts.

Taking this approach can result in improved energy efficiency and operational cost savings, and play a role in meeting goals your customers may have for sustainability, energy consumption and efficiency.

Why is whole building design a better approach?

“The whole is greater than the sum of its parts” is a common concept. Applying it to building design can provide significant value and results. For building owners and managers, it can result in improved energy efficiency, lower first cost and overall cost savings. For engineers and contractors, understanding and meeting customer needs with a systems-design approach can provide a competitive edge.

Rather than asking which individual pieces of equipment are the most efficient, the question becomes how to make the entire system more efficient? Resisting the urge to go granular immediately — and instead taking this systems approach upfront — helps maximize efficiency of the entire building.

It starts with understanding what the building owner or facility or property manager is trying to achieve in their facility. What building outcomes are being sought? Is the driver LEED certification, a net-zero building, a corporate sustainability goal or other benchmarks or regulations?

Next, consider how the building will be run and when it will be occupied. The needs of a commercial property differ greatly from the needs of a hospital, for example. Knowing how the building will be used provides a better understanding of full-load and part-load performance, which helps determine what equipment and systems are best suited for the building.

From there, move backward into what building systems best match these goals and needs. In addition, it’s important to look at how the various building systems — from plumbing, lighting, security and HVAC — interact and best work together to optimize building efficiency.

Consider this example: Many chilled water systems are designed to pump 2.4 gallons of water every minute for every ton of chilled water to be produced, and 3 gallons per minute of water for every ton of coolant to be made. If a chiller is selected based on these conditions, the end result is a lot of water being pumped around a building. By contrast, using a whole system approach can save significantly in the amount of water and energy used. While in this option the chiller may initially look less efficient, it actually uses much less pumping energy — especially at part-load conditions — and results in a much more efficient system-level performance.

As more organizations and states enact increasingly stringent energy-efficiency goals and regulations, the industry recognizes that systems-level efficiency provides a great opportunity for improvement in this area. The Alliance to Save Energy made a case for using a systems-level approach to improve energy efficiency in a recent white paper, “Greater than the Sum of its Parts.” The white paper notes that in addition to reducing energy use and associated costs to consumers, a systems approach has the potential to achieve significant non-energy benefits, including reduced greenhouse gas emissions, improved grid reliability and resilience, water savings, extended equipment life, and increased occupant comfort and productivity. Studies have estimated that the quantifiable non-energy benefits can add 25 to 50 percent to the total monetary benefits of energy efficiency.

Key strategies for a systems-level approach

Consider these key strategies that can help in successfully implementing a systems-level approach in building design:

• Understand the utility cost structure. Don’t choose building systems and equipment without having a clear understanding of the utility rates and structure for a specific building and location. Understanding the utility rate structure — which often includes consumption charges and demand charges — allows for a more accurate analysis of building performance based on how the building will be occupied and used. In some areas, demand charges can comprise up to 75 percent of the monthly utility bill. Knowing this can help in choosing the most efficient system from a utility bill perspective, such as taking advantage of the load-shifting capabilities of a thermal storage system. It’s often helpful to consult a partner who offers expertise in building systems and equipment, as well as in utility rate structures and billing.
• Consider the total budget. Selecting the building systems and equipment that will best provide optimized efficiency and performance for a specific building also hinges on the budget — both upfront and long-term for staffing and maintenance. Selecting a system that requires less long-term maintenance can help an organization save staffing costs in the long run.
• Understand the needs. Asking the right questions about how the building will be used and occupied is a critical consideration in choosing the systems and equipment that will provide the most efficient performance. For example, it typically takes several years after construction for most data center facilities to operate at full load. However, those early years of part-load operation are often not considered in building design when choosing the systems that will offer the most efficiency. It’s important to consider how systems and equipment will perform under partial loads.
• Use a modeling program. Using a building modeling or energy simulation program in building design contributes to sound decision making — and it can pay off in improved energy efficiency and performance. Modeling allows you to optimize the systems from an energy and utility bill perspective before construction even begins. It’s important to model against the potential optimized performance of the whole building and its systems, rather than modeling against performance of individual components.  

How can it pay off?

While improved energy efficiency and utility savings are significant benefits of system-level design, using this method can pay off in other ways.

Better fresh air ventilation or better acoustic levels in the building are examples of secondary benefits that can result from proper system design. These features can result in fewer complaints, as well as in more productive occupants.

Some systems also offer benefits for ease of maintenance and reduced risk down the road.

It is possible to use a single provider with expertise in equipment and system design and building optimization. This can help reduce risk and ensure a more efficient design and planning process. A knowledgeable partner can also help assess the best opportunities for efficiency.

Seeing the sum instead of the parts

What is it that your customers want to achieve in their building, and what is the best way to get those results? Considering these questions at the start of the design process can help in choosing the systems that are best suited for the job — and help your design stand out.

A building design process that focuses on the efficiency of the whole building — rather than on the efficiency of individual components — can improve energy efficiency and help you better meet the changing priorities of building owners.

Author Bio
Al Fullerton is Intelligent Systems Leader for Trane, a leading global provider of indoor comfort solutions and services and a brand of Ingersoll Rand. In this role, Al leads a team of engineers focused on expertly applying Trane Systems. Al has worked in the HVAC industry since graduating from the University of Cincinnati with a bachelor’s degree in Mechanical Engineering in June of 1981.  

By Drew Fellon, business leader for energy supply services, Trane

It’s well-known that energy costs are always one of the most significant portions of a commercial building budget. Finding ways to reduce that spend can be tricky, but there are ways you can impact it: reduce the amount of energy consumed, change the time of day energy is used, or reduce how much you pay for that energy.

Typically, reducing energy consumption is the go-to solution many building owners and energy managers use in an effort to reduce costs and improve sustainability. While this is an impactful way to decrease energy spend, there’s another, less-conventional strategy, that is often overlooked — even though it can yield significant savings — energy purchasing.

The obvious, though less common, solution is gaining traction in the industry as owners and managers explore ways to reduce their energy spend budgets. Developing a strategy for examining and assessing your energy procurement options can help you make the most of your commercial building budget.  

Consider these energy procurement best practices to help streamline the energy supply process, maximize savings and optimize efficiency in your next commercial building project.

Tip No. 1: Engage a knowledgeable partner

Energy procurement is a complicated process, compounded by the many factors that impact energy rates. Working with a reputable and knowledgeable partner makes the process easier — and can save your company money.

Energy procurement and management companies are powerful resources that can help you avoid spending too much on energy. These companies have long-standing supplier relationships and market intelligence capabilities that they leverage as they work with you through the procurement process and can assist you in getting the best deal possible. Using energy price forecasting, regulatory and legislative monitoring, and years of energy industry experience and contacts, an energy procurement and management firm can help you make insightful decisions to reach your company’s goals.

When choosing to engage an energy procurement and management company, select an experienced partner with insight into the full supply chain and industry pricing structure. This organization can provide visibility to the tens of thousands energy transactions taking place annually. Consider working with an independent advisor without ties to a specific energy company or market. This independence helps create loyalty to you, not the energy supply company, and will provide transparency throughout the procurement process.

The right procurement and management partner can help you navigate the energy purchasing waters — and prepare your company for trends that may impact the industry down the road.

Tip No. 2: Consider your goals

Saving money is typically the top priority for most energy and supply chain managers examining their energy procurement options. But as customers demand more efficient, environmentally conscious solutions for their buildings, many energy and supply chain managers are prioritizing sustainability and the use of renewable energy. When it comes to reaching these types of goals, you need to look beyond price in the purchasing process. It all comes down to what you’re trying to achieve.

If the goal is to reduce energy costs by 10 percent, then purchasing renewable energy is likely not the solution. And if you are hoping to reduce the company’s carbon footprint, you’ll need to buy a certain type of energy that may not always have the lowest price tag. All of which is to say, that putting sustainability first, can look very different than your typical energy procurement process and sources.

Because many energy contracts are long term (between 10 – 20 years), it’s important to take a comprehensive, enterprise-wide approach to buying renewable energy solutions. If your enterprise has buildings or operations in many states, you can achieve more buying power when you coordinate efforts.

Make sure you’re considering the total end cost of an energy contract. There are many factors that affect the final cost of an energy contract, and this may not be clear in every situation. An energy procurement and management firm can help you understand the total cost of the contract structure — not just the initially quoted supply price.

Tip No. 3: Link supply with demand

Before entering into a supply contract, you should fully understand all the factors that influence energy demand in your building — including the supply and demand relationship. Pay close attention to how much energy your building or enterprise uses, taking time to look at both prior and forecasted usage, to determine how much energy to buy.

It is imperative that the supply chain, which drives purchasing, communicates with the operations staff, who oversees day-to-day use of building facilities. Otherwise, the energy manager or supply side personnel may assume that because X amount of energy was used last year, X amount of energy will be needed again next year. When in reality, operations may plan to install a new production line or more energy efficient equipment that will impact the facility’s energy demand.

If your organization is going to take measures to reduce peak demand, you need to make sure your energy supply contract allows you to benefit financially — rather than potentially being penalized by your supplier. Demand-side reduction efforts should be negotiated into your supply-side contract. It’s also important to run a competitive bid process every time you seek a new supply contract, rather than allowing your current supplier to set the price. Doing so will help you secure the best deal for each new contract.

Tip No. 4: Plan ahead

Another common pitfall in energy procurement is waiting until just before the current contract expires to start looking for a new one. The energy market is seasonally cyclical and impactful market events can drive prices up or down for short periods. To avoid paying too much for your next contract, get an early start and take time to really dig into your options and review pricing. This is where working with an experienced energy procurement and management firm can yield big returns. Tracking the energy market daily and understanding how certain events will impact pricing over time are both critical to long-term buying success.

If your organization requires stakeholder approval of energy contracts, be aware of that and secure that approval in advance. This allows you to move quickly when the time is right, so you can lock in the best price. Not having the approval process in place could translate into delays and lost opportunities in terms of pricing, as prices are often only valid for a short period of time.

Purchasing with strategy

Your energy purchasing strategy is dependent on many things, most of which are out of your control. Weather, government regulations, demand charges, and new energy developments are all issues that can impact pricing for commercial customers. Taking control of your procurement options with thoughtful research, meaningful partnerships, conscious goal setting and extensive planning can help you make the right purchasing decision for your building. And remember that you don’t have to do it alone. Working with an experienced energy consultant can help you streamline the energy supply process to increase your savings.

Technical Safety BC’s recent report on the Fernie Arena tragedies underlines the safety risks inherent with ammonia ice plants. A small leak in a chiller tube caused a 9 lb. release of ammonia into the mechanical room which quickly overcame those working there.

To quote TSBC, “Ammonia releases from refrigeration systems can cause injuries to employees, emergency response personnel, any public using the facilities and those living in communities surrounding the facilities.  When released from a refrigeration system, ammonia vaporizes into a toxic gas. It is very corrosive, and exposure to it may result in chemical-type burns to skin, eyes, and lungs. It may also result in frostbite, since liquid ammonia’s boiling point at atmospheric pressure is -28°F. Ammonia has a high affinity for water and migrates to moist areas like the eyes, nose, mouth, throat, and moist skin.  Exposure to low concentrations can cause headaches, loss of the sense of smell, nausea, and vomiting. Higher concentrations result in irritation to the nose, mouth, and throat causing coughing, wheezing and damage to the lungs. Very high concentrations of ammonia can be immediately fatal.

Ammonia is flammable and extremely reactive as it readily combines with other chemicals to form other potentially harmful substances or explosive mixtures.  Material commonly found in refrigeration machinery rooms such as oils can react with ammonia increasing the fire hazard. In addition, strong oxidizers, such as chlorine or bleaches, can form explosive mixtures when they come into contact with ammonia.”

Work Safe BC calls ammonia levels of 300 ppm or more to be, “Immediately dangerous to life and health”.

The Trane white paper on Ammonia-Free Ice Rink Refrigeration, shows a leak of just a half pound is enough to raise the ammonia concentration in a typical equipment room above the 320 ppm RCL (Refrigerant Concentration Limit). Also notice it would require 718.8 lbs. of Trane’s R513A synthetic refrigerant to reach our 72,000 ppm RCL (well above the charge we have in our entire system).

Trane packaged chiller systems dominate the air-conditioning marketplace. As well our chillers are used in many institutional, industrial, laboratory, and critical cooling and heat recovery applications. Trane has built chiller systems for over a hundred years – it’s our bread-and-butter.

We are here to help you transition to safer, cost-effective and efficient ice rink chilling systems.

by Walter Linck

The way buildings are used — and the needs within building spaces — are continuously changing. Revitalization efforts turn abandoned warehouses into residential and commercial hot spots. Work place trends turn an old conference room into collaborative space or a wellness lounge.

Whether the changes are driven by corporate growth, new technology or shifting needs, building spaces must adjust. This is true for existing buildings and new construction.  

So how do you know what equipment and systems will meet your customers’ needs in your next building project? The answer is influenced by many factors — from upfront costs and ease of installation to integration with existing systems and flexibility for the future.

Key questions that drive next steps  

In planning your next building project, first consider a few key questions:

• What is the budget?
• How will the building be used and what are the operating hours?
• What is the building size?
• What are the energy and operational goals?
• Will the building be managed with on-site facility staff?
• How will results be measured?

The answers help you zero in on the right solutions and technologies to meet specific needs. A 50,000 square-foot building that is occupied 24/7 has very different needs than a 10,000 square-foot building that runs on a 9 to 5 schedule.

In choosing between the many heating, ventilation and air conditioning (HVAC) system options, consider these three factors to ensure the choice you make best meets your customers’ needs.

No. 1: Upfront costs versus long-term savings

Energy efficiency is a priority driving building design in many commercial spaces. Building owners and managers want solutions that improve efficiency, reduce costs and promote more sustainable building operation. Finding solutions that meet those needs results in more satisfied customers — making you more competitive.

Keep in mind that the most energy-efficient solution for a building may not be the option with the lowest upfront cost, just as the system with the lowest upfront cost may not be the most cost-effective long-term solution. There are trade-offs to consider when weighing these issues.

For example, are upfront cost savings so important that the building owner or manager would sacrifice long-term energy savings?

The right HVAC system is often determined by the size and usage of the building. Owners and operators of smaller commercial buildings may not have on-site facility staff, so they typically want a system that is easy to install, operate and maintain. Given these preferences, a unitary system is often a good choice for small commercial buildings.

With larger commercial buildings, there are more options to consider. Variable refrigerant flow (VRF) systems can provide affordable installation and energy efficiency over the life of the system. A chilled water system is another option in larger commercial buildings. These systems deliver high energy efficiency, but water-cooled chiller systems require ongoing water treatment and cooling tower maintenance.

Thermal energy storage can provide significant long-term cost savings by shifting a building’s energy use to off-peak hours when utility rates are lower. However, these systems are typically best suited to larger buildings because of the upfront cost and space requirements for installation.

While the project budget and priorities of the building owner are important, be sure to consider the return on investment. It’s important to look beyond upfront costs and consider the system’s long-term savings potential.

No. 2: Individual pieces versus whole building design

When specifying an HVAC solution, decisions are often made based on a single piece of equipment’s operating efficiency. But this is not the best way to achieve the most efficient building performance.

There are many variables that contribute to optimized building performance.

• How is the building being used and occupied?
• How do the various pieces of equipment in the building interact and work together?
• What are the energy goals in the facility?

Instead, we must look beyond the efficiency of a single piece of equipment and consider the performance and efficiency of the entire building. Seeing the whole as greater than the sum of its parts can result in improved energy efficiency and operational cost savings for building owners and managers. And meeting customer needs with a systems-design approach can provide you with a competitive edge.

Proper energy modeling will help you evaluate equipment and determine which options will make the entire building more efficient. It allows you to optimize the systems from an energy and utility bill perspective before construction even begins — and it can pay off in improved energy efficiency and performance.

No. 3: Balancing today’s needs with future growth

Replacing or upgrading a system in an existing building requires a different approach than specifying a system for a new construction project. In existing buildings, consider what types of equipment and systems are already in place. Then look for options that can be easily integrated with existing systems and building controls. Ease of integration is also a factor when designing new buildings that are part of an existing campus or network of buildings.

Leveraging technologies already in place is one way to uncover cost savings. A hybrid VRF system, for example, can connect to existing building systems — such as a chilled water system — using integrated controls. This can result in more cost-effective expansion in some buildings.

And because building spaces are constantly changing, it’s important to consider which solutions provide the greatest flexibility for future changes. Using wireless communication technology to connect devices is one way to improve ease of integration and ensure greater flexibility for changes.

A building where equipment and systems are connected in the cloud also enables efficiency and performance. In many buildings, existing systems can be easily integrated with open protocols, such as BACnet™ or Modbus™. This includes the building automation system (BAS), which can offer cloud-based connectivity and control of building systems.

This connectivity can provide access to intelligent services that extract the operating data from building equipment and systems and use the connection into a building to run advanced analytics. This data enables facility managers to make informed decisions and take actionable steps to help ensure a building runs a peak efficiency long term — not just on day one.

Keys to success

Considering your customers’ priorities — from costs to energy efficiency to reducing ongoing maintenance requirements — can help you choose the right system for your next building project. Help deliver long-term savings and results for your customer, while positioning yourself as a valuable business partner.