Wednesday, October 27, 2021

Energy Conservation Tips on Mother DairyPrint

Water use & waste water management

  • Always treat water as a raw material with a real cost. Water charges will continue to increase.
  • Water consumption varies from 1 to 5 litres for processing 1 litre of milk. High water consumption will make availability critical.
  • Water saved does’t hare to be in-house treated or heated.
  • Install water meters and monitor water use.
  • Use high pressure, low volume cleaning system.
  • Use automatic shut off nozzles on all water hoses.
  • Survey water use and waste production in the plant.
  • Improve maintenance to prevent product leaks from valves, piping and equipments.
  • Carry out waste water analysis. It is useful to indicate a plant’s processing efficiency including the product going down the drain.
  • Design and install lines that will allow proper draining of product rather than relying on rinse water to remove product.
  • Plan batch scheduling. Reducing the number of change overs will minimize losses of products.
  • Reuse process water from high volume pasteurizing unit.
  • Use reclaimed water
    • To supply boilers
    • For heating/cooling heat exchangers
    • For flushing products from process equipments.
    • For hose stations
    • For cleaning and sanitizing milk trucks.
  • Install screens on all drains.
  • Segregate strong acid or alkali waste streams and use them for pH control in waste water treatment.
  • Recover Heat from Milk Cooling systems while cooling from 390C to 30C for safe storage. The average preheated water temperature from water cooled condensing mechanism is likely to be in the range 500 to 600C.


Fuel Oil Handling and Operation:

  • For efficient combustion pre-heat the oil to have temp between 1050-1100C at burner tip and optimize air to fuel ratio.
  • To stop abrasive particles FO filtration system should have filter mesh sizes as follows.
  • a. Between Lorry & main storage tank-mesh size 10
    b. Between service tank & pre-heater- mesh size 40
    c. Between pre-heater and burner- mesh size 100
  • Provide water draining facility and regularly drain water. This reduces sludge formation and other problems like erosion of burners and damage to the refractories.
  • It is preferred to have parallel FO pumps of smaller capacity than one pump of larger capacity to avoid unnecessary re-circulation of huge quantity of FO.
  • Replace electric preheaters with steam coil preheater for DG set fuel since steam is cheaper source than electricity and is available at site.


Boiler and Accessories:

  • Control excess air with oxygen at 3.0 to 4% level in flue gas.
  • Air flow to fuel feed rate should be controlled for oxygen level around 3.0 % in flue gases.
  • Normally flue gas temperature is beyond 4000C. To recover waste heat install/replace air-preheater of required capacity and pre-heat the air.
  • Maintain TDS in boiler. If required install an automatic blowdown system.
  • Maintain stack temperature in the range of 1800-2000 C by oil pressure adjustment, burner cleaning, filtering fuel, soot & scale removal and excess air to 3 %. Any rise in flue gas temperature of more than 200C normal temperature soot blowing can be carried out.
  • Remove scale in ghee boilers to improve heat transfer which results in reducing steam consumption.


Condensate Recovery:

  • Condensate recovery from pastureizers, ghee boilers, milk packing can be used for hot water requirement for cleaning.



  • Improve insulation and cladding of DG sets exhaust
  • Insulate Flanges & valves to minimize heat loss. Insulation is to be of boxed type for maintenance ease.
  • Steam line, boiler feed water lines to be checked periodically and damaged insulation to be repaired immediately.
  • Improve insulation if the surface temperature exceeds 600C. Ensure that proper insulating material and thickness is provided for proper insulation.
  • Regularly check the cold insulation and repair them immediately to reduce heat loss.
  • Arrange or ask for Industrial training programme in your cluster once a year.


Cooling Tower:

  • Replace cooling tower conventional aluminum alloy blade with FRP blades of same profile.
  • Install automatic temperature controller for cooling water pumps.


Compressed Air:

  • Reduce compressed air pressure from 8 Kg/Cm2 to 7.0 Kg/Cm2 where ever possible to conserve energy, when required pressure at usage point is 6.0 Kg/Cm2
  • Stop use of compressed air for floor cleaning.
  • Check for compressed air leakage and arrest it.
  • Switch off one compressor if requirement can be met by balance operating compressors.


Refrigeration Compressor:

  • Maintain suction and discharge pressure as per design parameters. Higher discharge pressure may call for condenser dechoking, gas filling, cleaning of coils etc.
  • Water cooled condensers will reduce compressor running time.



  • Replace underloaded / overloaded motors with proper size motors. Replace the motors with energy efficiency motors.


Lighting :

  • Replace 40W Tube light by slim 28W Tube light and electromagnetic choke with electronic choke.
  • Replace 400 Watt Mercury Vapour lamps with 250 Watt sodium vapour lamps or 250 W metal hallide lamps.
  • Replace 250 Watt Mercury Vapour lamps with 150 Watt sodium vapour lamps or 150 W metal hallide lamps.
  • Provide more transparent sheet instead of asbestos sheets to use natural light.
  • Install energy saver for reducing the lighting load.
  • Rationalize lighting in identified areas i.e remove excess lighting in identified areas. Also relocate lighting, if necessary.


Contract Demand :

  • Provide demand controller with an alarm provision in case it exceeds contracted demand.
  • Review and reduce the contract demand.


Transformer :

  • If possible switch off one transformer running under loaded in parallel. Maintain all transformers at a loading of 70 to 80 % of rated capacity to minimize loss component (no load losses).
  • Try to have separate transformer for lighting where voltage can be kept low.


Power Factor :

  • Improve power factor by regular checking of current of all the capacitors and their timely replacement.
  • Install Automatic power factor correction device to have power factor of 0.99 to 1.00