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Exploring Energy Auditing in Dairy Industry

Conference Paper  in  IJIREEICE · April 2016

DOI: 10.17148/IJIREEICE/NCAEE.2016.18

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 ISSN (Online) 2321 – 2004
IJIREEICE ISSN (Print) 2321 – 5526

International Journal of Innovative Research in Electrical, Electronics, Instrumentation and Control Engineering

Nitte Conference on Advances in Electrical Engineering NCAEE-2016

NMAM Institute of Technology, Nitte
Vol. 4, Special Issue 2, April 2016

Exploring Energy Auditing in Dairy Industry

Vinutha K1, Anand Bhat B2, N. A. Ranjan3, M. E. Tejamoorthy4
Research scholars, E & E Department, MEC, Hassan, India1,2
Associate Professors, E & E Department, MEC, Hassan, India3,4

Abstract: Energy is the main concern of every one as the conventional sources of energy are depleting and there is a
notable growth in the industrial and domestic loads. To bridge this gap there is an immediate need to explore all
possible avenues to generate energy and conserve energy. A lot of interest has been generated in the conduct of energy
audits as a means to achieve energy conservation. With the advent of energy crisis and exponential hikes in the cost of
different forms of energy, energy audit is manifesting its due importance in various sectors. Dairy industry uses
electrical energy and thermal energy as main energy source. The total cost of energy plays a vital role in determining
the product cost of a commodity. Therefore the identification of potential energy savings and implementation for a
given industrial facility is important to ensure its competitive advantage over other similar industries. This paper
presents such energy saving methods in a methodological approach, experienced during a preliminary energy audit of a
large scale industry. The energy consumption and savings assessed in term of equipments used and its functional
purpose. Investing to improve the energy efficiency of a dairy industry provides an immediate and relatively
predictable cash flow resulting from lower energy bills.

Keywords: Energy sources, audit, consumption and conservation.

I. INTRODUCTION
India has emerged as the largest milk producing country in the world with present level of annual milk production
estimated as 94.5 million tonnes. The dairy sector consumes a significant amount of energy in its heating, cooling and
processing activities. Typical dairy plants derive about 70% of their energy requirements in the form of thermal energy
and the remaining 30% is consumed in the form electricity. In this direction the energy audit (EA) will help to
understand more about the ways energy and fuels used in the industry and helping engineers in identifying the areas
where waste can occur and scope for improvement.

Here the dairy industry has been considered, to explore the energy conservation opportunities. Energy audit was carried
out in Nandini Hi Tech Product Plant (NHPP) situated at Channarayapatna, Hassan Dist (Karnataka), a strategic
location to handle the surplus milk of 4 lakh liters from Hassan, Mandya, Mysore, Shivmoga and Tumkur milk unions.

II. ENERGY AUDIT

A. Distribution system
The plant receives electricity from CESCOM (Chamundeshwari Electricity Supply Corporation Ltd.,) at 11KV with
contract demand of 1500kVA and supply power to plant through two distribution transformers. The plant has stand-by
DG (Diesel Generator) sets of capacity 1010kVA and 200kVA. Transformer 1 supplies power to refrigeration, LMP
(liquid milk processing) plant and capacitor bank. Transformer 2 supplies power to powder plant, boiler, ETP (Effluent
treatment plant) sections, lighting purpose and capacitor bank.
Table 1 gives the section wise connected and operating load details of the plant.
Table 1 Load Details (section wise)
SI. Connected load Operated load
NO Name of Feeder in HP in HP
1 Powder Plant 1350 1200
2 Dairy Plant 700 500
3 Refrigeration 933 666
4 Boiler 163 62
5 ETP 65 49
6 Lighting 175 105
TOTAL 3386 2582

B. Demand side management

The audit begins with a detailed analysis of the energy bills of the previous twelve months. This is important because:
the bills show the proportionate use of each different energy source/load when compared to the total energy

Copyright to IJIREEICE DOI 10.17148/IJIREEICE/NCAEE.2016.18 91

 ISSN (Online) 2321 – 2004
IJIREEICE ISSN (Print) 2321 – 5526

International Journal of Innovative Research in Electrical, Electronics, Instrumentation and Control Engineering

Nitte Conference on Advances in Electrical Engineering NCAEE-2016

NMAM Institute of Technology, Nitte
Vol. 4, Special Issue 2, April 2016

consumption. An examination of where energy is used can point out precisely unknown energy wastes. The total
amount spent on energy usage decides the commodity rate.

Over and above, one year energy bills of NHPP dairy were collected from the concerned authorities and analyzed.
Table 2 gives the details of energy bill for the years 2014-2015. The analysis of 2014-2015 energy bills reviled the load
factor. In addition, milk input, output products and cash flow details were analyzed for the same years. Before March-
2015, Powder Plant was completely running by Diesel Generator (DG) set to avoid the change in quality of powder due
to any unavoidable interruption in power supply, which automatically leads to CIP (clean in place) mode, for an hour.
The remaining section power requirement was taken care by CESCOM supply. Due to this, there was poor utilization
of contract demand (1500kVA) and plant average maximum demand was 739.3 kVA (year 2014) and it can be
observed in Fig. 1. Due to under utilization of MD (maximum demand) the company was bearing Rs. 191250 per
month upto March-2015. 1200kVA UPS (uninterrupted power supply) at a cost of 1.35 crores was installed separately
for powder plant operation which provides 30min backup under power interruption from April-2015. The CESCOM
now provides electrical energy for all the sections including powder plant for dairy operation. This helped dairy in
meeting its maximum demand.
Table 2 Energy bills for years 2014 and 2015 for NHPP
Demand Energy
MD kWh Total
charges charges kVAh Tax
Month reading meter PF Rebate charges
@170 rs @5.35 reading @6%
(kVA) reading (Rs)
@340 rs @5.65rs
Jan-14 389.55 191250 1296507 234780 239445 0.95 77790.42 44767.5 1520880
Feb-14 401 191250 1051410 325662 342803 0.95 63084.60 - 1254096
Mar-14 491.85 191250 1492618 269490 274065 0.98 89557.11 61590 1711836
Apr-14 784.05 191250 1439904 260160 264735 0.98 86394.24 55323.75 1662224
May-14 960 191250 1590720 271012 274590 0.98 95443.20 42877 1834536
Jun-14 757.95 191250 1280220 218370 219915 0.99 76813.20 76813.2 1332098
Jul-14 790.8 191250 1520166 258361 263055 0.98 91519.99 38790 1769575
Aug-14 821.25 191250 1496760 254460 257595 0.98 90110.95 42082.5 1736865
Sep-14 825 191250 1424940 242490 255775 0.99 85787.39 40301.25 1666726
Oct-14 828.15 191250 1764600 299100 308775 0.97 105876.00 50475 2010652
Nov-14 825 191250 1567500 266250 274395 0.97 94050.00 37803.75 1815197
Dec-14 997 191250 1772610 300435 310785 0.97 106356.60 55061.25 2006388
Jan-15 529.8 191250 1693590 287265 294285 0.99 101615.40 46856.25 1939600
Feb-15 961.65 191250 1276710 217785 222780 0.96 76602.60 24963.75 1519598
Mar-15 800 191250 2522850 425475 435000 0.97 151371.00 91875 2769810
Apr-15 1295.7 220320 4000125 655305 659745 0.99 24007.55 15470 4061946
May-15 965.25 191250 2979564 489360 493935 0.97 178773.84 10255 3221440
Jun-15 0 191250 3575314 586230 590100 0.97 214518.88 8411 3832584
Jul-15 1212 206040 3597085 589770 591225 0.99 215825.12 9581 3870946
Aug-15 1380 234600 4057597 664650 669390 0.97 243455.84 9677 4356911

Fig. 1 Variation in MD as a function of time in month.

Copyright to IJIREEICE DOI 10.17148/IJIREEICE/NCAEE.2016.18 92

 ISSN (Online) 2321 – 2004
IJIREEICE ISSN (Print) 2321 – 5526

International Journal of Innovative Research in Electrical, Electronics, Instrumentation and Control Engineering

Nitte Conference on Advances in Electrical Engineering NCAEE-2016

NMAM Institute of Technology, Nitte
Vol. 4, Special Issue 2, April 2016

C. Performance evaluation of DG sets

1010 kVA DG set is kept as a standalone supply for powder plant under CESCOM powder interruption. Separate 200
kVA DG is taking care of other sections during power failure.
Before UPS installation the powder plant was operated by DG set of 1010 kVA continuously throughout the day.

Specific Energy Calculation

Number of units generated
Specific energy =
Total amount of fuel consumed in liters
273432
Specific energy = = 3.18 units / liters.
85985

Average units generated per liters of fuel for a span of 7 days is 3.02 units / liters.
Each liter of diesel costs Rs.59.315 (as per 2014 rate),
59.315
Therefore cost of production of 1 unit = = 18.65 Rs.
3.18

From Table 3 it can be observed that diesel consumption is reduced considerably from Mar-2015. After installation of
UPS, the company savings from the diesel fuel cost is brought down by Rs. 30 lakhs per month. The payback period for
installation cost of UPS was within 8 months.
Table 3 Operating details of DG sets form Jan-2014
Specific
Quantity Units
Rate/Lt Total Amount Energy
Month Consume Generated
(Rs) (Rs) (kWh/L
d (Lts) (kWh)
itre)
Jan-14 81720 58.51 4781437 281934 3.45
Feb-14 60920 59.12 3601590.4 201036 3.30
Mar-
73975 59.47 4419266.5 242638 3.28
14
Apr-14 64929 59.47 3878858.46 220759 3.4
May-
83285 60 5078390.75 270676 3.25
14
Jun-14 87184 60.52 5276375.67 289450 3.32
Jul-14 85060 61.6 5239696 272192 3.2
Aug-
79451 62.21 4942646.71 266955 3.36
14
Sep-14 78409 62.82 4925653.38 257966 3.29
Oct-14 81235 59.58 5159950.25 255890 3.15
Nov-
85985 56.58 4865031.3 273432 3.18
14
Dec-14 94855 51.9 4922974.5 294050 3.1
Jan-15 89622 47.04 4440880.84 293960 3.28
Feb-15 69425 44.7 3087209.55 231185 3.33
Mar-
46858 47.35 2219068.28 157443 3.36
15
Apr-15 8150 47.34 385821 27547 3.38
May-
4630 47.24 218721.2 15186 3.28
15
Jun-15 4680 47.22 220989.6 15912 3.4
Jul-15 1655 47.22 78149.1 5379 3.25
Aug-
8635 41.02 354207.7 28496 3.3
15
Sep-15 6899 40.55 279754.45 23456 3.4

III. ENERGY CONSERVATION OPPORTUNITY

Since plant is already installed with energy efficient motors and VFD‟s (variable frequency drives) no energy
conservation is possible in this area. Energy audit process sighted possibility of energy conservation in lighting and
boiler loads.

Copyright to IJIREEICE DOI 10.17148/IJIREEICE/NCAEE.2016.18 93

 ISSN (Online) 2321 – 2004
IJIREEICE ISSN (Print) 2321 – 5526

International Journal of Innovative Research in Electrical, Electronics, Instrumentation and Control Engineering

Nitte Conference on Advances in Electrical Engineering NCAEE-2016

NMAM Institute of Technology, Nitte
Vol. 4, Special Issue 2, April 2016

A. Energy conservation in Lighting

Objective of lighting system management is to improve the quality of lighting while minimizing energy consumption.
Lighting in this dairy industry can be grouped as
a) Low power lighting loads and
b) High power lighting loads.
During energy audit it was decided to replace some of these lighting gadgets with energy efficient lamps (EEL). For
example, CFL are replaced with LED. With these change, it is expected that the same lighting intensity can be obtained
with reduced wattage.
Company has long straight roads leading to different sections and staff quarters. It also has focus lighting is Metal-
halide lamps of capacity 150W each. It is suggested to replace it by LED lamps, thus reducing both energy and
maintenance cost with long life.

Annual saving by implementing these suggestions is shown in Table 4. Taking Rs. 5.85 per unit as tariff, annual
savings works out to be Rs 3,23,503.83.

Table 4 Anticipated annual energy saving with Energy Efficient Lamps (EEL)
SI. Savings
Details
No (units)
1 Replacement of (11W×2) CFL to 14W LED 700.8
2 Replacement of (36W×2) CFL to 30W LED 2759
3 Replacement of (70W) MH to 30W LED 51840
Total 55299.8

B. Energy conservation in Boiler

There are two boilers in dairy each of same capacity and its details are given in Table 5.The boiler is a huge energy
guzzler and thermal energy saving can be achieved by many methods.

Table 5 Rating of Existing Boilers

Characteristics Boiler 1 Boiler 2
Working pressure (kg/cm2) 14.5 14.5
Working temp (°C) 100 100
Evaporation capacity
4500 4500
(kg/hr)
Company Forbes Marshell Forbes Marshell
Fuel used Furnace oil Furnace oil
3 pass smoke
Type 3 pass smoke tube
tube

1) Energy efficient fuel

Furnace oil is used as fuel for the boilers; its calorific value is 9650 kCal/kg and is available at 18 Rs/kg. In place of
FO, agro fuel like „Briquette‟ which is made by agricultural wastes can be used. Briquette calorific value is 3800 –
4000 kCal/kg and it costs 5.1 Rs/kg, which is economical, easily available and environmental friendly.

2) Economizers
Steam generation in a boiler requires feed water that is often a mixture of returned condensate and treated make up
water. Flue gases from large boilers are typically 230 – 340°C (450 - 650°F). Stack Economizers recover some of this
heat for pre-heating water. Boiler stack economizers are simply heat exchangers with hot flue gas on one side and water
on the other. An economizer that recovers 5% of boiler input should easily have a 2 year payback in a year-round
application. Since present boilers fuel gas temperature is 240°C, economizer can be installed.

Calculation of waste heat recovery from economizer

Flue gas temperature at outlet of boiler burner =240ºC
Feed water temperature = 30ºC
Water consumption per hour = 4200 kg/hr
Specific heat of water = 4.19 kJ/kg C

Copyright to IJIREEICE DOI 10.17148/IJIREEICE/NCAEE.2016.18 94

 ISSN (Online) 2321 – 2004
IJIREEICE ISSN (Print) 2321 – 5526

International Journal of Innovative Research in Electrical, Electronics, Instrumentation and Control Engineering

Nitte Conference on Advances in Electrical Engineering NCAEE-2016

NMAM Institute of Technology, Nitte
Vol. 4, Special Issue 2, April 2016

Heat required for rising temperature of water is given by

Q = S × m × ΔT
Where, S = specific heat of water
m = mass of water (flow rate)
ΔT = temperature difference

Lowest considered flue gas temperature coming out of boiler = 180ºC

Maximum temperature of flue gas available = 240 – 180 = 60°C
Heat transfer efficiency between airs (flue gas) to water is 70%
Rise in feed water temperature = 60 × 0.7 = 42ºC
Feed water temperature at outlet of economizer = 30 + 42
= 72 ºC

Assumptions
1. Steady operating conditions exist
2. Effectiveness of the heat exchanger remains constant
Maximum heat recovery in heat exchanger
Qmax = S × m × ΔT
= 4.18 kJ/kg ºC × 1.167 kg/s × (72 – 30) ºC
= 204.88 kJ/s

A heat exchanger of reasonable size and cost can capture 75% of this heat transfer potential
Q = 0.75 × Qmax
= 0.75 × 204.88
= 153.66 kJ/s

The heat exchanger operates 24h a day & 356 days a year.
Operating hours = 24 h/day × 365 days/year
= 8760 h/year
Energy saved = heat transfer rate × operating time
= 153.66 kJ/s × 8760 h/year × 3600 s/h
= 4.846 × 109 kJ/year

Furnace efficiency is 80%

Heat energy produced by 1 kg FO = 40375.6 kJ/kg
Energy savings converted to Rs/year is
Fuel saved = Energy saved / Furnace efficiency
= 4.846 × 109 / 0.8
= 6.06 × 109 kJ/year / 40375.6 kJ/kg
= 150028.73 kg/year

The price of FO is 18 Rs/kg, the amount of money saved will be

Money saved = Fuel saved × Price of fuel
= 150028.73 kg/year × 18 Rs/kg
= 27, 00,517.14 Rs/year

Therefore, the installation of the proposed heat exchanger will save the company Rs 27, 00,517.14 a year, and the
installation cost of the heat exchanger will probably be recovered from the fuel savings in a short time.

3) Solar water heater

Solar water heater can be installed for preheating the feed water using solar energy thereby reducing the use of fossil
fuels. The above potential of energy conservation requires minor changes in pipeline arrangement of feed water, solar
panel installation and hot water storage tank integrated with existing system. The life of solar water heating plant is
around 15-20 years.

The risk involved in installing the above proposal is high cost. Bur MNRE (Ministry of New and Renewable Energy)
provides opportunities and incentives for Technology and Quality upgradation support to micro, small and medium
enterprise.

Copyright to IJIREEICE DOI 10.17148/IJIREEICE/NCAEE.2016.18 95

 ISSN (Online) 2321 – 2004
IJIREEICE ISSN (Print) 2321 – 5526

International Journal of Innovative Research in Electrical, Electronics, Instrumentation and Control Engineering

Nitte Conference on Advances in Electrical Engineering NCAEE-2016

NMAM Institute of Technology, Nitte
Vol. 4, Special Issue 2, April 2016

IV. CONCLUSION
Calculation has been done on the basis of measured/ collected data. Reduction in electricity bill is possible, thus
making the industry eco friendly. Set of suggestion is highlighted in conserving energy by minimum resource
mobilization at the boiler which works for 24×7 continuously with pay-back period. Economic feasibility of adopting
solar gadgets is also recommended to the concerned for further study. Majority of the suggestions is readily accepted
for further study and implementation of the same.

ACKNOWLEDGMENT
Authors wish to thank authorities of Nandini Hi Tech Product Plant (an unit of KMF), Channarayapatna, Hassan for
providing the necessary facilities to carry out the work in the esteemed organization and also initiating us to publish the
outcome.

REFERENCES
[1]. Nissanga Nishad Rasanajan Mendis, Nisal Perera: “ Energy Audit: A Case Study”, 1-4244-0555 6/06/$20.00 ©2006 IEEE.
[2]. John Upton, Michael Murphy: “Dairy Farm Energy Consumption”, Teagasc National Dairy Conference 2010.
[3]. Detailed Project Report on Renewable Energy Harnessing (10000 LPD Solar Water Heater) Technology, Gujarat Dairy Cluster, Gujarat (India).
[4]. Swapnil Ratnakar Mane: “Energy Management In A Dairy Industry”, Energy Science & Engineering, IIT Bombay, Mumbai.
[5]. Yunus A. Cengel and Afshin J. Ghajar, Heat and Mass Transfer, Mc Graw Hill Education,2013.

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