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Saving Energy in the Beverage Manufacturing Industry

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If you are planning to start a small to medium sized beverage manufacturing unit (including soft drink, alcohol and bottled water) then this crucial information will be helpful in:

• Saving energy and money
• Increase efficiency
• Improve your environmental performance

Here’s an insight on practical and cost effective energy saving options. Managers can make use of these options to reduce the amount of energy used in activities such as: processing; cleaning; monitoring and testing; packaging; and warehousing.

Benefits of saving energy

Improving energy efficiency will help saving energy, also aid businesses and the environment in various ways:
• Process improvements and increasing plant and equipment efficiency will reduce the energy costs.
• Proper control on energy-related greenhouse gas emissions will help in reducing the environmental impact of your business.
• Extending equipment life, reducing operating costs and avoiding downtime increases energy efficiency.
• Improving the reputation of your business and providing a safer and more comfortable workplace to employees.

Methods of saving energy

• Chillers consume more energy. So by avoiding overloading cool-rooms and over cooling items, you can reduce chiller energy intensity. Review (and raise if feasible) temperature settings of cool rooms.
• Operate air compressors at the lowest possible settings (e.g. operating at 830 kPa (120 psi) instead of 690 kPa (100 psi) requires 10% more energy but may not be necessary). Locate the compressor air intake where the ambient air temperature is as low as possible.
• Turn off air conditioners, compressors, boilers, water heaters when not in use. Use timers to switch them on with sufficient lead time.
• Review air-conditioner settings and widen the temperature band if feasible (e.g. 21-24°C).
• Use extraction fans only when equipment is in use. Make use of natural ventilation rather than mechanical ventilation where possible.
• While purchasing new plant and equipment consider both operating and purchasing cost. Energy efficient equipment may be slightly more expensive to purchase, but will cost less over the life of the equipment.
• Implement a preventive maintenance program as it would help prevent all equipment failure before it occurs.
• Maintain cool rooms by regularly checking door seals and refrigerant levels of chillers. Turn off compressors when not in use. Insulate pipe work and locate refrigeration heat exchangers away from heat sources such as radiators and air conditioning systems.
• Maximize the use of natural lighting by installing sky lights with reflective tubes to light areas that are difficult to reach.
• Retrofit variable speed drives (VSD) to motors so that motors can deliver the required loads with less energy and wear and tear.
• To reduce heat loss, make use of boiler valves, steam and condensate return pipes and storage units.
• Capture waste heat from boilers through flue gas heat recovery (~5% energy saving) into incoming water or from boiler blow down flash steam.
• Make use of sensors for conveyors and other auxiliary plant operation to prevent excessive running and energy consumption.

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