Checking the steam network at a carbonated beverage production facility revealed that the steam condensate is not recovered, leading to loss of water and energy. Installing a condensate recovery network is a feasible alternative to conserve natural resources.
It was noted that this dairy and juice company consumes volume of water to rinse the system during the CIP exceeding the benchmarked quantities. Reducing the water quantities over small steps, while monitoring the product quality lead to conservation of water and energy.
Modification to the process in order to have a prewashing stage before the boxes are emptied to the sterilization station saved significantly on water, energy and reduced the pollution load.
The pasteurization temperature within a juice manufacturing company was allowed to exceed the set limit. Maintaining the pasteurization temperature at the defined set point shall save on energy use.
A carbonated drinks facility used diesel fuel to operate its boiler despite it was connected to the natural gas grid. Replacing the boiler’s burner with one that can fire natural gas, and increasing the contracted capacity for natural gas was found as a feasible measure to maintain economic benefits and reduce the pollution load.
A milk and beverage company suffered from repeated power outages, thus relied on diesel generators to maintain production availability. The triggers for the generators were not optimized to recharge after short power outages, leading to occasional cuts, forcing CIP to start. Adjusting the triggers of the generators shall eliminate untimely shutdown of equipment.
Water mapping in a textile company revealed several opportunities to conserve on water and thermal energy through process optimisation and energy efficient design.
A beverage and juice manufacturing company had an oversized, obselete design compressor running at low load factor. This caused excess energy consumption. Replacing the compressor from a piston type compressor to a smaller size rotary-screw type compressor shall increase the efficiency of the compressor, and reduce the unload time which is a waste of energy.