Reducing energy consumption

The food processing sector is notoriously competitive and a volatile energy market has placed further pressure on already tight operating margins. Now more than ever, manufacturers are turning to technology to gain a better understanding of their energy consumption with a view to either retaining or regaining a competitive advantage. The following technology-led advice will offer a route to energy savings:

Switch it off: While it may sound obvious, one of the quickest wins for food processing plants looking to curb unnecessary energy consumption is to turn off any equipment when not in direct use. For many, the prevailing thought may be that energy consumption for powering up or down equipment may be greater than leaving it idle in between cycles. However, unless this is backed up by data then the thought is likely to remain conjecture. 

Implementing an energy management platform at asset level will take data that is probably already being collected and extract it in a way that helps visualise the specific energy use of individual applications. In turn, this data-led insight can help processors identify potential inefficiencies to address and optimise both demand side management and workflows accordingly.

Optimise the performance of existing plant: Another easy-to-implement solution which can deliver significant energy savings is to install variable speed drives (VSDs) where applicable. Whilst this is not a ground-breaking solution, I am always amazed when I visit a site and see direct online (DOL) motors used throughout the plant. Mitsubishi Electric was able to reduce the weekly electricity consumption of one large food processing plant in Ireland by 89% – from 6113 kWh to 664 kWh – through the implementation of a demand management system and the replacement all DOL motors with VSDs.

Consider a third-party energy audit: You cannot measure what you don’t know. Using an independent, third-party energy consultant, such as ‘MyCarbon,’ will give you an impartial overview of your current energy usage and distil it into actionable insights. Not only will this provide a holistic view of opportunities to improve energy consumption, which will in turn impact profitability; but it can also help  reduce both scope two and three carbon emissions while also contributing to the Courtauld Commitment. 

Go beyond the production line: Extending the energy management platform remit beyond the production line provides food processing plants with opportunities to cut back usage. Whether it is HVAC or lighting systems, applying the same approach to critical building infrastructure and services can contribute to reducing the plant’s energy consumption.

Diversify the energy mix: While optimising the energy performance of plant equipment and workflows will help improve demand side management, another option for food processors is to diversify the source of the energy itself. The use of microgrids in production environments continues to grow, driven both by the impact of the energy crisis and ESG commitments. From solar PV and on-site wind generation through to battery storage systems, introducing local renewable energy resources into the energy mix can give more flexibility and control when it comes to managing energy generation, usage and cost.