Follow these 10 tips to improve production line efficiency in food and drink manufacturing and cut energy costs in your plant as well as meeting industry sustainability targets.
Reducing energy waste in manufacturing and improving production line efficiency is essential if manufacturers are to comply with mandatory greenhouse gas emissions regulations and EU targets - and it’ll also help lower energy bills.
Here are 10 ways that energy and facilities managers can improve the efficiency of their production line.
1. Optimising the use of refrigeration and chilling, which can account for up to 50% of a site’s energy costs.
- Prevent overcooling to minimise energy costs and improve efficiency.
- Maintain systems and pipework - ensure they are not blocked, dirty or leaking.
- Upgrade or replace inefficient equipment.
- Switch off lighting in refrigeration areas when not in use.
- Keep refrigeration doors closed and prevent cool air from escaping.
2. Regularly maintaining boilers and heating distribution systems. Poorly operating boilers add 30% to heating costs.
- Ensure burners are working efficiently, or replace them.
- Switch off burners when not required - install automatic controls.
- Upgrade or replace inefficient boilers to improve efficiency in the production line.
- Fit heat recovery systems to boilers (especially gas), e.g. reclaim heat energy for use in process preheating.
- De-steam non-critical systems and replace with less expensive hot water systems.
3. Ensuring pipework is well insulated (refrigeration, heating and steam systems).
- Insulation should be in good condition.
- Pipework should take the shortest route to minimise potential energy losses.
4. Operating costly compressed air systems efficiently.
- Switch off idling air compressors, as they can still use 40% of their full load.
- Reduce the system pressure wherever possible.
- Carry out regular maintenance.
5. Improving lighting systems.
- Fit high efficiency lighting and controls - this can reduce energy costs by 30%.
- Fit motion sensors in unoccupied areas to automatically switch off lights.
6. Correctly sizing motors and drives for their application. This can reduce running costs by 3%-5%.
- Switch off motors when not in use - fit auto sensors to control operation.
- Install higher efficiency motors.
- Fit variable speed drives to pumps and fans.
7. Initiating water saving measures.
- Ensure water systems are well maintained.
- Recycle process water.
- Fit self-closing taps.
8. Using process measurement and control – this can cut energy costs by up to 10%.
- Ensure process equipment is utilised and controlled efficiently.
- Equipment should be regularly calibrated.
9. Integrate energy management systems.
- Fit meters to electrical equipment to monitor system efficiencies and determine where further energy savings can be made.
- Turn off equipment when not in use, i.e. at night and on weekends.
10. Consider Combined Heat and Power (CHP)
- Achieve energy cost savings of up to 40% and reductions in CO2 emissions of up to 30%.
- Install CHP as a replacement for inefficient boilers or alongside existing boilers – generate efficient electricity and heat energy from a single on-site process.
Find out more about improving the performance of your production line by downloading: How to shrink the carbon footprint of your production line (without sacrificing efficiency)
Topics: Food and Drink Manufacturing