I have recently come across a brief report on possible energy cost reduction projects in industrial baking prepared in the UK by Carbon Trust.
Key points of this article:
Tried and true solutions for efficiency
- In order to estimate costs for improvements and energy savings, the starting point is to ensure that you have good sub-metering, to precisely determine current consumption.
- Savings of 4.7% for bread ovens are possible by linking variable flue gas speed drives with combustion control
- Large quantities of energy are lost through oven flues and exhausts. Opportunity for heat recovery. Low-grade heat can always be used in baking industry
- combustion conditions are often not monitored other than during burner servicing, this causes inefficient combustion conditions. An opportunity to save up to 10% of natural gas
- Timely maintenance of motors leads to saving up to 7% of electricity. Proper maintenance on compressors can save up to 10%. This work must be done anyway, why not do it on time and save on energy?
- Preheat combustion air with exhaust gases.
- Compressed air leakage is ‘in fashion’ for many plants despite being the lowest hanging fruit. The only still lower fruit is turning compressors off when plant is not working
- Automation reduces human errors and energy consumption. IIoT technologies provide continuous insight into what’s happening on production floor in real time
- ultrasound humidification technology to bake bread; it helps to reduce energy consumption and also maintains the quality of the bread.
- Infrared ovens are being adopted by commercial bakeries worldwide. Reduce energy by 50-80% and reduce time by 2/3.
- Reflective coatings that contain high-emissivity ceramic materials reduces energy use by 20-30%. Increase oven lifespan.
- Multilevel ovens are also helping commercial bakeries become more energy efficient and allow for higher flexibility in production process
Read the whole article here.