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

PERFORMANCE INDICATORS• Annual energy variation factor

• Specific Energy

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

THANK YOU