SEMINAR ON

Food Processing
 History The history of processed food is the rationalization of advanced technology related to raw material treatment operations, processing operations, storage operations, other processing equipment, cleaning of facilities, sterilizing and conservation treatment operations and effluent and waste treatment operations.  Origin Egypt (3000 to 5000 BC)  Foundation of modern industry was built with the introduction of machinery and technology of new methods from Germany

Energy Consumption

Source: Analysis of energy efficiency development, 2010

Benefits of Conserving Energy

Reducing energy costs through process improvements Increasing plant and equipment efficiency Reducing the environmental impact through minimizing energy-related greenhouse gas emissions Extending equipment life, reducing operating costs and avoiding downtime through increased energy efficiency and improved maintenance regimes

Classification of Food Manufacturing Industry

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HIGH ENERGY CONSUMING AREAS

Energy Conservation Technique

PROCESS IMPROVEMENT EQUIPMENT IMPROVEMENT GOOD HOUSEKEEPING

ENERGY MANAGEMENT

Energy consumption chart Data analysis and measuring Consumption and purposes of energy use

Quantity of energy used

ENERGY FOR PRODUCTION

The energy required for a process and its he service : Product energy loss The energy required for containers and equipment : Loss of Equipment energy Energy lost due to control : Loss of Control energy Energy lost due to energy conveyance and control : Loss of Supply energy Loss due to the purchase and generation of energy : Loss of Generation energy

Fuel expenses, electricity Expenses and water expenses

Energy Conservation Techniques in Steam Generation & Distribution System

Contd Adopt biomass-based boiler Arrest fuel oil leakage. Even a small oil leakage of one drop per second can result in wastage of 4000 liter per year of fuel oil. Provide gauges for steam pressure and temperature on boilers and temperature gauge in the flue gas outlet Analyse flue gas regularly by using portable flue gas analyser. Optimize excess air in the boiler.
5% reduction in excess air = 1% increase in boiler efficiency 1% reduction of residual oxygen in the flue gas = 1% reduction in fuel consumption

Contd
Observe colour of the smoke coming out of the boiler

Contd
Use economizer or air pre-heater Every 6C rise in feed water temperature by heat recovery or condensate recovery corresponds to a 1% saving in fuel consumption in the boiler The boiler tubes should be cleaned regularly
1mm thick scale (deposit) on the water side of boiler tubes = 5%8% increase fuel consumption

The boiler should be checked for any soot and fly ash deposition on the fire side of boiler tubes.
3mm thick soot deposition on the heat transfer surface = 2.5% increase the fuel consumption

Recover and return condensate to the boiler, as it still carries about 15%20% of the total steam energy.

Contd

Steam piping inspection

Steam leakage If a 2mm hole is opened in a 5kg/cm2 pressure steam pipe, 9kg per hour of leaked steam, or 6480kg per month of leaked steam, will be diffused into the air and wasted. This is equivalent to about 500 liters of fuel oil. Where, D : hole diameter (cm) P : steam pressure (kg/cm2) V : specific volume of saturated steam(m3/kg)

Contd

Insulation

 Care is taken not to get the insulation wet.  Insulating all steam pipes inside an air-conditioned factory is effective.

Contd Use air vents to remove the trapped air from the jacketed vessel as air acts as insulator and reduces the heat transfer Resistance to heat transfer by 0.25mm thick air film = resistance to heat transfer by 330mm thick copper wall For all indirect steam heating, use steam at a lowest acceptable pressure, since the latent heat of steam at lower pressure is higher.

Contd

Efficient steam trap management in the plant

Contd
Flash steam recovery When hot condensate is subjected to a sudden pressure drop, a portion of the condensate vaporizes back into steam. Because saturated water on a lower pressure level can only contain less energy. The excess energy is used to create a certain amount of steam at the lower pressure level. The percentage of steam generation is known as flash rate.

Compressed Air System

Efficiency of the compressed air system, from generation to enduse, is less than 10%

Typical sankey diagram for a compressed air system

Contd

The air intake to the compressor should be clean, cool and drawn from a place, which is away from the heat sources. Every 5C rise in suction air temperature will increase power consumption by 2% Compressor discharge pressure should be kept at minimum acceptable level
Increase of 1 kg/cm2 air discharge pressure (above the desired) from the compressor = 4%5% increase in input power

Use two compressors catering , if compressed air is required at two different pressures.

Contd Air intake filters should be cleaned at regular intervals to facilitate clean air intake of compressor and low pressure drop across it. Avoid compressed air use for cleaning. Air blowers are well suited for such applications as they generate large volume of air at lower pressure with lower energy consumption Change the oil filter regularly. All the compressed air piping should be laid out in such a way that it minimizes pressure drops during transmission. Pressure drops in a smaller compressed air system < 0.3 bar

Contd

Prevent leakages of compressed air at various areas like coupling, hoses, fittings, pressure regulators, valves, pipe joints, and drain traps.
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Electrical Distribution System

Provide capacitor at the load (motor) end to have the benefit of reduced distribution loss (for example, line losses, and cable loading). Maintain the power factor at the main feeder greater than 0.9 to avoid penalty and further improve it to above 0.95 to avail the rebate Control the maximum demand by tripping the non-critical loads through a demand controller.

LIGHTING
y Make the maximum use of daylight by providing translucent roof

sheets, glass window, etc. y Replace all the incandescent bulbs with CFL (compact fluorescent lamp).

CONTD
y Develop the habit of switching off the lights whenever not required y Clean the lamp and fixture regularly for better lighting efficiency y Immediately replace the fused tube light to avoid choke losses in

tube light fitting without any useful lighting

y Replacement of mercury vapour lamps with 70 W low pressure

sodium vapour (LPSV) lamp, for street lighting or the area where colour rendering is not important, will result in 40-50% electricity savings.
y Consider painting the inner walls with a lighter colour. This will

require less number of lighting fixtures.

MOTOR
y Strategic motor selection
y Always use properly sized motors as per the load application

Variation in efficiency and power factor with load for a typical motor

Contd...
y 20% reduction in motor speed will result into almost 50% y y

y y

power savings All new replacements should be done with energyefficient motors having 3-5% higher efficiency It is better to replace the old motor which has undergone rewinding 3 times. Motor efficiency goes down by 3-5% after each rewinding The motor should be rewound by a qualified person. If a motor is continuously running below 45% of its design load, it is better to operate it in star mode by changing to star connection or by installing auto delta-star converter.

CONTD.
y It is appropriate to use VSD (variable speed drive) with the motor y Even a 1% unbalance will reduce motor efficiency at part load

y y y y y y y

operation, while a 2.5% unbalance will reduce motor efficiency at full load operation. Motor management plan Creation of a motor survey and tracking program Development of guidelines for proactive repair/replace decisions Preparation for motor failure by creating a spares inventory Development of a purchasing specification Development of a repair specification Development and implementation of a predictive and preventive maintenance program

PUMPS
y By changing pumping equipment and/or pump control

systems, 20% of total energy consumption can be saved y Pump system maintenance: Lead to energy savings of 2-7% y Replacement of worn impellers, especially in caustic or semi-solid applications y Bearing inspection and repair y Bearing lubrication replacement, on an annual or semiannual basis

CONTD . Inspection and replacement of packing seals. Allowable leakage from packing seals is usually between 2 to 60 drops per minute Inspection and replacement of mechanical seals Checking of pump/motor alignment Inspection of motor condition, including the motor winding insulation

Pump System Monitoring

Wear monitoring Vibration analysis Pressure and flow monitoring Current or power monitoring Monitoring of differential head and temperature rise across pumps (also known as thermodynamic monitoring) Distribution system inspection for scaling or contaminant build-up

Pump Demand Reduction

Use of holding tanks and the elimination of bypass loops Lead to energy savings of 10-20% Lower process static pressures Minimize elevation rises in the piping system Lower spray nozzle velocities

Properly Sized Pumps

Replacing oversized pumps with pumps that are properly sized can often reduce the electricity use of a pumping system by 15-25%

REFRIGERATION SYSTEM

Maintain the suction and discharge parameters of the refrigerant as recommended by the manufacturer for efficient chilling/refrigeration operation. Switch off the chiller compressor as soon as the required temperature is achieved. Condenser coils should regularly be cleaned. A scale build-up of 1 mm on condenser tubes can increase energy consumption by 40% All the lights in the cold storage/refrigeration chamber should be kept off

CONTD

Plug the refrigerant leakages as soon as they are identified. All the doors of cold storage/refrigeration chamber should be tightly closed to avoid the infiltration of outside air Remove all the excess surface water from the fruit/vegetable/corn before refrigeration as it will lead to extra energy consumption by the refrigeration compressor. Avoid frost formation on the evaporation coils in the blast freezer and cold storage by regular defrosting

Cooling Towers
y Switch off the cooling tower fan when loads are reduced y y

y y

or during night/colder months Clean the distribution nozzles in the cooling tower regularly to have uniform distribution of water. Aerodynamic FRP (fibre reinforced plastic) fan blades can reduce the fan energy consumption by 15-20% in cooling towers Avoid idle operation of cooling tower and circulation of cooling water to an application that is not operating. Keep water in the cooling tower basin free of algal growth

Energy Efficiency Measures for Blanching

Upgrading of steam blanchers Energy efficiency features of modern steam blanchers Steam seals Insulation Forced convection Process controls Recovery of condensate

CONTD

Heat and hold techniques

Reduce blanching times by up to 60% and blanching energy intensity by up to 50%

Heat recovery from blanching water or condensate Steam recirculation

Energy Efficiency Measures for Drying and Dehydrating

Maintenance: Decrease energy consumption by up to 10% Checking burner and combustion efficiency. Checking heat exchangers for fouling, excessive pressure drops and leaks. Cleaning filters at fans. Checking for belt slippage and fan speeds. Avoiding air leaks through checks and repairs of doors and seals.

CONTD Checking and repairing insulation on burners, heat exchangers, duct work and the body of the dryer. Checking thermocouples and humidity sensors for fouling. Monitoring heat transfer efficiency. Ensuring that fuel and air ports and flues are clear of debris. Checking and repairing utility (i.e., steam, natural gas, and compressed air) supply lines.

CONTD Insulation Mechanical dewatering: For each 1% reduction in feed moisture, the dryer energy input can be reduced by up to 4% Direct fired dryers: Direct fired dryers can reduce primary fuel use by 35-45% compared to indirect Exhaust air heat recovery Using dry air Heat recovery from the product Process controls

Energy Efficiency Measures for Evaporation

Maintenance
Inspection and prevention of air leaks into evaporators to minimize venting rates Cleaning of heat transfer surfaces to allow efficient transfer of energy. Inspection and replacement of wet, damaged, or decayed insulation. Cleaning of vapor separation vessels to maintain product yields and pressure profiles. Inspection and prevention of water leaks into the system to avoid diluting the product streams. Maintaining the optimum pressure profile in the evaporator per the manufacturer s specifications

Energy Efficiency Measures for Frying

Heat recovery from fryer exhaust gases Heat recovery via exhaust gas combustion Heat recovery via adsorption cooling Using spent fryer oil as fuel

Energy Efficiency Measures for Pasteurization and Sterilization

Sterilizer insulation Heat recovery from pasteurization Compact immersion tube heat exchangers Helical heat exchangers

Latest Techniques for Efficient Use of Energy

Whenever new process equipment is bought it should have better efficiency even if the cost is higher All new steam using equipment (vats, blanchers, indirect heaters, and so on ) should have proper steam seals to stop steam leakage, proper insulation to minimize heat loss through surface and process controller (with temperature indicators) to regulate steam flow based on the product.

CONTD Infrared heating could be a more efficient option. Solar energy is available in plenty (an average radiation of 4-5 kWh/m2/day)and should be explored for possible use in food industry Waste generated from the fruits and vegetables based industry can be used for biogas generation, which could be used for heat generation.

ENERGY AUDIT
Indicates the ways in which different forms of energy are being used and quantify energy use according to discrete functions. Energy audit is broadly classified as:
Preliminary energy audit Detailed energy audit

Preliminary Energy Audit

Step 1: Identifies the quantity and cost of the various energy forms used in the plant. Step 2: Identifies energy consumption at the department/process level. Step 3: Relates energy input to production (output), thereby highlighting energy invest in energyefficient technologies wastage in major equipment/processes.

Detailed Energy Audit

Study involves detailed mass and energy balance of major energy-consuming equipment System efficiencies are evaluated and measures are identified for improving the end-use energy efficiency Study proposes specific projects/feasibility studies for major retrofitting/replacement proposals, providing a cost-benefit analysis of the recommended measure Duration of the audit is a function of the size and complexity of the plant

General Guidelines
Dos Undertake regular energy audits to identify energy saving potential Sensitize plant personnel on the benefits of energy conservation Encourage people to provide ideas for energy savings and reward them Promote group activities for information sharing at cluster level Search constantly for energy-efficient technological solutions Avail external expertise to develop and undertake technological up-gradation Participate in workshops and training programs on energy efficiency improvements Share success stories and discuss energy efficiency improvement strategies with co-entrepreneurs

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Dont's

Do not be stagnant Do not look for only short-term benefits Do not be afraid of adopting new technologies Do not always depend on in-house technical capacity Do not think low-cost solutions are always economical Do not be apprehensive to approach banks for loans to invest in energy-efficient technologies

CONCLUSION
Energy is an important basic input in food manufacturing process There are 3 steps in energy conservation and management
GOOD HOUSEKEEPING EQUIPMENT IMPROVEMENT PROCESS IMPROVEMENT

By using EMS plants can save about 5%10% of their energy costs

CONTD

Regularly undertake energy audit Meter the energy consumption Optimize the equipment usage Switch off lights, motors, equipment, and so on when not in use Replace old/inefficient equipment with the new and more efficient ones Whenever buying a new motor always opt for high efficiency motors Make maximum use of day-lighting by using translucent sheets on roof and glass windows Replace exhaust fans with air circulators wherever possible