ENERGY UTILISATION AND EFFICIENCY IN SMALL SCALE FOOD PROCESSING INDUSTRIES NAME: EGESA JESSE COURSE: Bsc. MECHANICAL ENGINEERING 2013 SUPERVISOR: DR JOHN BAPTIST KIRABIRA CO-SUPERVISOR: MR KASEDDE HILARY
Jul 28, 2015
ENERGY UTILISATION AND EFFICIENCY IN SMALL SCALE FOOD PROCESSING INDUSTRIESNAME: EGESA JESSECOURSE: Bsc. MECHANICAL ENGINEERING 2013SUPERVISOR: DR JOHN BAPTIST KIRABIRACO-SUPERVISOR: MR KASEDDE HILARY
PROBLEM STATEMENT• Common to all food processing industries is an
energy requirement which constitutes large proportions of budgets alongside raw materials and labor.
Bakery
Grain Miller
0% 10% 20% 30% 40% 50% 60% 70% 80%
35%
68%
Production cost Proportion
PROBLEM STATEMENT CONT’D• Energy, though vital, is also an increasingly
costly investment in manufacturing.
OBJECTIVESMAIN OBJECTIVE
• To devise means of improving energy efficiency in food processing industries
SPECIFIC OBJECTIVES• To determine the current energy utilization in food processing industries
• To investigate & identify factors causing energy wastage & potential opportunities for savings
• To propose measures to be taken so as to yield energy savings
METHODOLOGYCOLLECTION METHODS• Plant inspection: Observations• Examining of historical energy & production records• Interviews and meetings• Questionnaires• Desk Research
DATA COLLECTED• Forms of energy used• Historical energy use and production levels• Current operating practices and procedures
METHODOLGY CONT’D• Analysis was done using MS Excel
• Tables • Charts• Graphs
• Computation were made using standard formulae• Annual energy variation factor• Specific energy consumption
• Interpretation and discussion of data• Conclusions & Recommendations• Documentation
ANALYSIS: ENERGY VS. PRODUCTION COSTS
Energy Raw Materials Labour Other costs
Grain Miller 0.68 0.15 0.06 0.11
Bakery 0.35 0.3 0.15 0.2
-5%
5%
15%
25%
35%
45%
55%
65%
Perc
enta
ge C
ontr
ibuti
on
ANALYSIS: ENERGY CONSUMPTIONA
pri
l
May
Jun
e
July
Au
g.
Sep
t.
Oct
.
Nov
.
Dec
.
Jan
.
Feb.
Mar
ch
0
10
20
30
40
50
60 Grain Miller Bakery
Months April 2012 - March 2013
Cost
in U
GX
mil
lion
Sh
illi
ngs
ANALYSIS: CONSUMPTION VS. PRODUCTION
April
May
June July
Aug.
Sept
.
Oct
.
Nov
.
Dec
.
Jan.
Feb.
Mar
ch
0
5
10
15
20
25
30
0
5000
10000
15000
20000
25000
30000
Electricity Charges Number of loavesMonths April 2012 - March 2013
Elec
tric
ity
Cahr
ges
in U
GX
mill
ions
Prod
ucti
on
LOA
F BA
KE
RY
ANALYSIS: CONSUMPTION BREAKDOWNLO
AF B
AK
ERYSlicing
Baking
Proving
Dividing
Mixing
5% 15% 25% 35% 45% 55% 65% 75% 85% 95%
Slicing Baking Proving Dividing Mixing
Percentage power re-quirement
0.004 0.96 0.02 0.006 0.01
ANALYSIS: CONSUMPTION VS. PRODUCTION
April
May
June
July
Aug.
Sept.
Oct.
Nov.
Dec.
Jan.
Feb.
March
0
20
40
60
80
100
120
0
20
40
60
80
100
120
Total Production Power ConsumptionMonths April 2012 - March 2013
Ene
rgy
Cons
umpt
ion
in U
GX
mil
-li
ons
Pro
duct
ion
in to
ns X
10 G
RA
IN M
ILLER
PRODUCTION BREAKDOWNG
RA
IN M
ILLER
April
May
June
July
Aug.
Sept.
Oct.
Nov.
Dec.
Jan.
Feb.
March
0
200
400
600
800
1000
1200
Jico (Wheat) Maize Soya Other TotalMonths April 2012 - March 2013
Prod
uctio
n in
Ton
s
WHEAT PRODN. vs. POWER CONSUMPTION
April
May
June July
Aug.
Sept
.
Oct
.
Nov
.
Dec
.
Jan.
Feb.
Mar
ch
0
10
20
30
40
50
60
0
100
200
300
400
500
600
Power Consumption Wheat ProductionMonths April 2012 - March 2013
Pow
er c
onsu
mpti
on in
UG
X m
illio
ns
Whe
at P
rodu
ction
in to
ns GR
AIN
MILLER
MAIZE MILLING DEPARTMENT• Oldest Department on the premises• Greatest changes in power requirement over the
years
New Plant (2011 - Present)
Improved Plant (2007-2011)
Original Plant
15.67%
66.67%
100.00%
Maize Plant Power Requirement Over the years
GR
AIN
MILLER
SPECIFIC POWER CONSUMPTIONA
pril
May
June
July
Aug
.
Sept
.
Oct
.
Nov
.
Dec
.
Jan.
Feb.
Mar
ch
0
0.5
1
1.5
2
2.5
0
0.05
0.1
0.15
0.2
0.25
Bakery Grain Miller
Months April 2012 - March 2013
BA
KER
Y k
Wh
/kg
Gra
in M
ille
r kW
h/k
g
Low Levels of Production
High levels of Production
CONCLUSIONSBased on the specific objectives of the study;
• Utilization of energy was determined across processes
• Analysis of data helped identify areas of energy wastage• Heating of 2 unused ovens at The Bakery• The use of wet firewood at (Grain Miller)• Under loading of machines (Grain Miller)• Higher rated machines than necessary (Grain Miller)
• A number of recommendations were made.
RECOMMENDATIONS• Introduce electric switches for individual ovens
• Result in savings of 40% i.e. UGX 1,762,176 per day.
• To improve utilization; purchase another Prover & mixer
• Consider purchasing newer ovens; could present energy savings of 40% at baking stage.
LOA
F BA
KE
RY
RECOMMENDATIONS• Use only dry firewood to fuel bread oven
• Results in faster oven heating and up to 50% savings
• Ensure that automated maize milling plant is always in running condition
• Saves UGX 895,859.2 / day over the old line • New 60Hp motor costs UGX 9.5 million, value would
be recovered within 11 days
• Increase feed opening on mills in soy department.
GR
AIN
MILLER