Energy savings for the manufacture of sugar confectionery items

Transcription

1 Energy savings for the manufacture of sugar confectionery items

2 Member of Group

3 Wernigerode 180 Employees Hannover Bad Salzuflen 350 Employees Built 1995 NEW: Nov Extended 2001 Modernized m² extension

4 Inside our Lab Customer trials up to kg / hr

5 How Chocotech offer energy savings Electrical Energy Use of IE3 motors, 2% energy savings

6 How Chocotech offer energy savings Steam instead of electrical energy Steam heating for water tempering units, i.e. tanks, piping etc. Energy savings, steam costs much lower compared to electrical energy Chocotech hygienic skid designed water tempering unit for jackets of tanks and product piping Water tempering, 11 x Loops

7 How Chocotech offer energy savings Insulation of piping and tanks, 3 6% energy savings Triple skinned hygienic product piping Hygienic Skid Design Insulation Jacket Product

8 dpmin=50mbar Energy Savings How Chocotech offer energy savings Energy Recovery System SUCROTWIST Brüdenabgang über Dach Schichtenspeicher max. Temp. 80 C Use of exhaust vapors for heating water Water can be used for tank / pipe heating and / or CIP water Dampf Eingang: Ansatz A% TS Nebenluft Ausgang: gekochtes Produkt B% TS Brüdeneingang 0,95bar / 100 C Kühlwasserrücklauf C über Durchsatz regulierbar Kühlwasservorlauf C abhängig von Speichertemperatur Brüdenausgang 0,9bar / 30 C-80 C Brüdenkondensat C Brauchwassererwärmung bis 70 C Tankheizkreislauf bis 60 C Beide Verbraucher für Abwärmenutzung müssen zusätzlich noch über eine konventionelle Wärmequelle verfügen. CHCOCTECH kann Wasserzirkulationsgeräte liefern, die Dampf- oder Elektroheizung mit der Einkopplung der Speicherwärme verbinden. Brüdenmenge= Duchsatz x ( A% B% -1) Wärmeinhalt Brüden ca kj kg 20% Restbrüden werden nicht kondensiert nutzbare Wärmemenge = 0,8x Brüdenmenge 3600 x 2200 kj kg

9 The biggest and most innovative energy saver in our portfolio is the Ecograv Steam savings of up to 50%

10 What is the Ecograv? Sugar Consists of: 1. Gravimetric batch weigher 2. Buffer tank to go from batch infeed to continuous production 3. Feed pump 4. Integrated pressure dissolver Glucose

11 How does the Ecograv work? Uses the moisture in the glucose to dissolve the sugar without adding additonal or very little process water. This allows CHOCOTECH to start the cooking process at 90% solids instead of the conventional 80% solids. Result: Steam savings of up to 50%

12 Hard Candy Line, 3 colours & flavors, capacity 2000 kg / hr Example of savings

13 Hard Candy Line, 3 colours & flavors, capacity 2000 kg / hr Example of savings Conventional System Autograv Solids in 80% Solids out 98 99% Steam Requirement 665 kg/hr Ecograv System Solids in 90% Solids out 98 99% Steam Requirement 350 kg/hr Steam savings = 314 kg/hr x hrs (1 x Shift, 1 Year) = kg/ pa Steam price per kg 0,05 x kg steam = ,- per shift / pa

14 Fondant Line kg / hr Steam savings = 233 kg/hr x hrs (1 x Shift, 1 Year) = kg/ pa Steam price per kg 0,05 x kg steam = ,- per shift / pa

15 Chewy Candy Line kg / hr Steam savings = 250 kg/hr x hrs (1 x Shift, 1 Year) = kg/ pa Steam price per kg 0,05 x kg steam = ,- per shift / pa

16 Sugar solutions for Nougat (Bar Lines) kg/hr Steam savings = 165 kg/hr x hrs (1 x Shift, 1 Year) = kg/ pa Steam price per kg 0,05 x kg steam = ,- per shift / pa

17 Lab Ecograv

18 What type of products can the Ecograv be used for? 1. Hard Candy / Medicated hard candy 2. Chewy Candy 3. Fondants 4. Sugar solution for bar making

19 Ecograv Patented system Energy (steam) saving up to 50% Big savings on potable water in recipe Less vapors to condense due to higher infeed solids Flexible system due to gravimetric metering of ingredients

20 Ecograv Patented system Available in sizes: kg / hr

21 Ecograv Patented system Ecograv 90/50 Available in sizes: kg / hr Ecograv 90/2200

22 Summary 1. Electrical energy using IE3 motors. 2. Steam for water tempering units. (Instead of electrical heating) 3. Insulation of product piping/tanks. 4. Energy Recovery (Exhaust vapors for water heating) 5. Ecograv for dissolving. (Steam savings)

23 The presentation today was based mainly on energy savings rather than energy recovery. Because the less energy you use the less you have to recover. We have to continue to look at a simple but efficient ways of reducing energy costs and the Ecograv is a very good example of how this can be done. Ecograv introduced at Interpack 2011 Units integrated into kitchens and sold?? Orders pending 2014??

24 Innovation: Productivity: Sustainability: - Continuous incremental improvements - Important process patent awards - Flexibility, what you want and not what we have - Stabile processes and operator friendly systems - Longer continuous production runs - Product reclaim (Inline) - Efficient CIP loops - Short start up and shut down procedures of kitchens - Professional operator training - Long and positive history in the industry - Inhouse Apprenticeship and Engineering Programme - Continuous growth and investment - SIS (Service Information System) planned Maintenance

25 3.000 m² extension to factory, completed February 2014 Thank You