Approximately 67 % of digitally active Indians are environment friendly and claim to prefer eco-friendly products – including food and beverages, claimed a survey by The Euromonitor International. The current times has only brought about an increased awareness amongst consumers to evaluate the health and environmental impact of their purchases.
Strong demand for convenient, healthier foods and beverages – produced and packaged in the most environmentally friendly way possible – is placing critical importance on sustainability at every stage of the value chain. Existing resources like land and water which are critical for agriculture are facing an increased pressure, warranting a need for the food industry to move towards more energy efficient operations.
Increasing energy efficiency
Today, the way the world perceives energy consumption has changed drastically. India is one of the largest food producers in the world, and hence also one of the largest users of power for food processing. It has become crucial now to reduce our carbon footprint and conserve the energy resources we have.
The first step is to pinpoint the most significant sources of energy usage. Look at where, when, and how much energy is being used across various applications. The Food and Beverage industry uses a lot of power thanks to the different processes that involve constant heating, cooling and at times aerating or brewing.
Since each process involves different speed requirements, it becomes essential to stop and restart motors or use different motors at different stages. The solution to this can be motors with Variable speed drives (VSDs) and high-efficiency motors which not only reduce downtime but also aid in energy conservation.
Electric motors usually make up the bulk of a plant’s energy consumption, however the good news is that there is a significant opportunity to reduce electricity usage by upgrading from less efficient motors to ultra-premium motors, like the IE5 synchronous reluctance motors (SynRM).
These motors use magnets thus amplifying the electricity generated which is then passed on to the machines, thereby minimising the usage of electricity and reducing the overall carbon footprint. Adding variable speed drives to existing motors or generators can also have a significant impact on energy savings. Companies can even use specialised tools available to calculate the amount of energy and money they could save by installing drives.
Traditionally, most motors in factories run at full speed even when they are not required, resulting in energy wastage. Drives like VSDs allow for more control over a motor by adjusting the speed or torque according to the actual need. The motor thus only draws the power needed to perform the task, cutting waste. Replacing throttle valves with VSDs for better pump control is another way to save energy. Adding VSDs can unlock energy savings to its full potential – with a strong chance to reduce energy consumption between 20 to 60 percent.Â
Smart sensors for pumps and/ or motors can help with spot energy saving opportunities. Data collected from these sensors, combined with information collected from VSDs’ inbuilt sensors and loggers, can be collated, stored, and further accessed via cloud technology. The ability to gather and analyse this data can reveal information that can be used to make performance improvements that will increase efficiency.
Optimizing water usage
Water footprint is as high a priority today as is carbon footprint. Most food and beverage manufacturing units need to use water directly (operational) or indirectly (supply chain and cleaning). Activities such as cutting, dicing, slicing, and filleting generate a large volume of wastewater. High-pressure cleaning also consumes vast quantities of water. Minimizing water usage for process equipment and pipeline cleaning presents another challenge for food manufacturers. It is essential to mark the water usage not only at the production units but also at every stage of the process chain.
One solution is to implement efficient pumping by using VSD pump controls to help optimize water usage. These controls offer several critical software functions such as regulating the pressure and flow rate for pipe clean and fill functions in Clean-In-Place (CIP) equipment. This reduces the cleaning time, resulting in less water and cleaning materials being used. Anti-cavitation software can also detect and prevent cavitation to ensure the optimal flow of water throughout the plant an extending the pump’s lifetime. Another way to save water is to choose products that are very easy to clean – taking less time and requiring less water such as hygienic, stainless-steel washdown motors, gearboxes and mounted bearings designed with smooth, crevice-free surfaces.
The beverages industry can also benefit from smart sensors to detect and calculate the actual water needed for each process.
Running a more sustainable, energy-efficient food and beverage manufacturing plant is possible by the use of technology to minimise carbon and water footprint. In a world where corporate responsibility includes environmental consciousness, focusing on energy efficiency can help companies position themselves in a more favourable light with their stakeholders. At the same time, saving energy also contributes directly to greater profitability and meeting minimum energy efficiency legislation.