Horizon Milling, Rush City, counts on ECE for energy-saving strategies
Cargill Horizon Milling in Rush City, MN, one of 20 flour mills in the company's national network, has become a business unit leader in the energy efficiency of its filtration system, and they've done it with the help of East Central Energy.

According to plant Manager Mike Ginal, the use of variable frequency drives (VFD) in the filtration process has been "the big driver" in reducing the mill's energy consumption.

In the past five years, the mill has completed six different energy-efficiency projects in the areas of lighting, motors and adjustable speed drives. The investments have reduced their demand by 30.36 kW and their electricity use by 172,912 kWh annually. They save over $7,600 each year in energy costs.

Ginal said his work with ECE's Strategic Accounts and Community Development staff "has been a total education. They take the time to work with me, to explain the processes, to help me with proposals," he said.

"We have a great partnership," Ginal added, "not just because of the cost reductions we've achieved by working together. They're colleagues and friends we trust. ECE is part of our team here at the mill."

ECE moved beyond its role as energy advisor last spring, when rail service to the mill was indefinitely interrupted due to a damaged bridge in Pine City, MN.

"One hundred percent of our raw material comes in on rail," Ginal said, and 90 percent of our product goes out that way. Without a rail, we don't exist."

The mill, with 28 employees, has a major impact on the local economy. Concerned that it might be permanently shutdown, ECE staff and community leaders from throughout the area worked to make sure that didn't happen. National, state and local officials were contacted to ask that the bridge be repaired. Federal funds were allocated, and rail service was restored when the bridge was re-opened in December. Ginal worked with ECE on additional electrical improvements during the shutdown.

"It's about communication," he said of his relationship with ECE. "I feel very lucky to know my ECE account representative, to know people at ECE. Our operation is proof that you can save energy, even at an older facility like this mill."