Case StudySeptember 2017

ChallengeMaking spirits at the Jeptha Creed Distillery starts with

creating the mash. The cooking process begins with grinding

the corn, which is then heated in water to get the starches

accessible, before adding a combination of wheat, rye and

barley to convert the starches to sugars. Yeast is added to

the product during fermentation, after which the product is

distilled, a process which heats the product to a vapor in order

to separate the alcohol from the flavor components. With large

amounts of heat and steam used in the distillation process,

the distillery had a great need for chilled water to cool the

vapor to convert it back into liquid. “Our challenges were not

so much with the HVAC needed for comfort cooling, but with

the chilled water required for the distillation process,” said

Joyce Nethery, owner, CEO and master distiller, Jeptha Creed

Distillery. “We had some really big chilled water needs. We

were looking for an economical way to cool the mash, and we

needed to do it quickly, which meant a lot of BTU load.”

SolutionKnowing of Trane’s extensive work on the process cooling

side of the distillery market and experience using thermal

storage, the mechanical engineer working on the Jeptha Creed

Distillery building design introduced Trane to the project. The

Trane team began the process of selecting the right equipment

to handle the distillery's process cooling needs, adhering to

industry-specific process cooling requirements.

A family-owned craft distillery, Jeptha Creed Distillery was born out of the owners' background in farming and chemical engineering, and their desire to build a legacy. Holding true to its motto, “Don’t Forget Where You Came From,” the distillery uses old-fashioned brewing methods and locally-sourced ingredients, such as its signature Bloody Butcher corn, as well as berries, apples and mint grown on the 64-acre property. For more information, visit JepthaCreed.com.

Built from the ground up, the 15,500 sq ft Jeptha Creed Distillery includes a production area, a warehouse for raw materials and finished goods, office space, a gift shop, and a cocktail bar.

Jeptha Creed DistilleryThermal storage system answers process cooling needs; shifts demand load; results in energy savings of more than $20,000 a year • Shelbyville, Kentucky

Determining the right equipment

Unlike an office building, hospital or school, in the distillery

environment, Trane knew special consideration must be given

to electrical classifications because of the product's potential

flammability. In addition, the Trane team evaluated the facility’s

chilled water demand needs, which fluctuate throughout the

day due to the batch loading of the distillery process. With 40

to 60 percent of the distillery’s electricity bills coming from

demand costs, Trane engineers sought to spread out the peak

electrical loads of the chilled water system, instead of having

30-60 minute spikes throughout the day. Rather than looking

at a single day of the distillery process, Trane analyzed an

entire week to determine the right equipment sizing.

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Shifting demand to reduce energy cost

A thermal storage system was implemented to shift demand

from peak-load production process times to lower-cost, off-

peak hours, significantly reducing energy demand costs. The

system includes a Trane CGAM air-cooled chiller, two CALMAC®

IceBank® energy storage tanks, and a custom-designed ice

completion module with an all stainless steel pipe pump

package. Running with glycol for freeze protection, the system

converts from glycol to a chilled water system to serve distillery

processes. The Trane chiller operates loaded most of the time

when the distillation process is not running, building up ice in

the storage tanks to provide capacity to handle the operation’s

needs throughout the week. The ice cools the distillation

process for one or two mashes a day, after which the tank

is recharged. Instead of using a 200 to 250-ton chiller to

handle the load that the process might require over a one-

hour period, the thermal storage system spreads out demand

loads, allowing the use of a smaller 40-ton chiller. The high-

efficiency Trane CGAM chiller not only helps to lower energy

use, but delivers the lowest noise levels in its class, providing a

comfortable environment for workers and guests.

Commissioning for optimal flow

A Trane® Tracer™ SC building automation system (BAS) and a

Tracer UC600 programmable unit controller were installed as

part of the ice completion module. With remote access, Trane

used the Web-enabled controls system during the start-up and

commissioning phases to make small adjustments to frequency

drives and differential pressure settings to balance the systems

and get proper flows through the equipment, as the owners

were going through initial production runs. Ongoing, the

controls system will provide the distillery with visibility into

chilled water process temperatures and pressures.

ResultsImplementing a thermal storage system for process chilled

water cooling has resulted in significant energy savings for the

Jeptha Creed Distillery. The system has enabled the distillery

to shift demand, allowing the use of a smaller 40-ton chiller

combined with ice storage, instead of a larger 200 to 250-

ton chiller to serve the distillery’s process needs. The result is

an energy savings of $20,000-$30,000 a year. “The system

provides the chilled water we need, when we need it, at the

temperature we set," said Nethery. "There have been no delays

in the process because we didn’t have chilled water. I don’t

have to think about my chilled water; it is just there.”

(Trane, the Circle Logo, and Tracer are trademarks of Trane in

the US and other countries. Calmac and Ice Bank are registered

trademarks of CALMAC Manufacturing Corp. All trademarks

referenced are trademarks of their respective owners.)

The thermal storage system is located outside, so as not to occupy floor space needed for the production process or other business functions.

©2017 Ingersoll Rand CASE-SLX470-EN September 18, 2017