Astra Foods – Upper Darby, Pennsylvania2019-07-12T10:52:45-04:00

Project Description

Astra Foods – Upper Darby, Pennsylvania
Cogeneration Plant – 2 MW

Key Project Statistics:

  • Turnkey: Engineering, Construction, and Commissioning
  • First Year Operation
  • 2 MW Gas Engine
  • 100 HP Waste Heat Recovery Boiler, Clayton
  • Dual Temperature Hot Water Recovery for Process Heating and Domestic Hot Water Cleaning
  • Modification to: Steam Plant, Gas Infrastructure, Electrical Sub-Station
  • $3.4 Million Construction Cost
  • PA Act 129 and PA Clean Energy Funds
  • Schedule: 6 months Engineering, 12 months Construction
  • Cost Savings after 1 year were within 10% of forecast
  • Allen Bradley, ZFED Automated, ReD™ Microgrid Controller
  • Reference: Spiros Poulimenos, President Astra Foods, 484-431-4030

Relevant Experience:

  • Engineering and Construction of Combined Heat & Power Plant
  • Island Mode with Manual Load Shedding Requirement
  • Black Start Capabilities
  • Strict Sound Requirement, Neighboring Residential Community
  • Operation and Maintenance Contract
  • Compact Design for Small Footprint

Z&F provided a complete turnkey installation of a 2 MW cogeneration plant for Astra Foods, Inc. in their manufacturing facility. The project included a gas fired engine, steam generators, and domestic water heaters. The facility was fully automated to buy and sell power on the wholesale market according to up to the minute market conditions. The complete installation of this project realized a gross Return on Investment (ROI) of approximately 3.5 years. When tax credits and Act 129 rebates were considered, the ROI was less than 2.5 years.


Z&F Consulting has the experience, knowledge and capacity to successfully complete an assignment in a professional, cost-effective, and timely manner.