Energy Systems Analysis and Renewable Energy for Manufacturing

This report presents an executive summary of an analysis of energy systems within a small manufacturing company, specifically focusing on beer production. The study identifies the most significant energy-using processes, including mashing, cold processes (fermentation and filtration), and packaging. It highlights energy consumption patterns, emphasizing the use of thermal energy in mashing and electrical energy in cold processes. The report details methods for measuring energy use and calculating energy efficiency, while also outlining major energy losses within the brewing sector. Furthermore, it explores the suitability of renewable energy technologies, such as photovoltaic solar projects, to enhance sustainability and reduce costs. The report recommends specific strategies, including CO2 recovery systems and the optimization of compressed air usage, to improve overall energy efficiency and reduce greenhouse gas emissions. The conclusion emphasizes the importance of integrating renewable energy solutions for a more sustainable and cost-effective manufacturing approach.

LOW IMPACT MANUFACTURING-
INDUSTRIAL ENERGY SYSTEMS

EXECUTIVE SUMMARY
This assignment is based on understanding the energy systems at a small manufacturing
company. The project discussed all several processes in manufacturing of beer that has been
classified into three sections such as mashing (hot process), cold process and packaging. Herein,
the most significant energy using processes includes both mashing and cold process. In context
to the cold process, consumption of electrical energy is more because of the processes of
fermentation and filtration. The fermenter is used in combined form with centrifuging and the
filtration procedure is mainly related with the cooling process through employing coolers. To
bring sustainability factor in this age’s old manufacturing company, it is important to bring
modifications by focusing on the renewable energy technologies. This would offer several
options in cost reductions and laid the foundation of enhancing the energy efficiency. For
example, by applying the Photo-voltaic solar projects in the premises would lead to a more
profitable approach. This assignment has summarized that there are many significant energy
using processes within this company which has been explained and estimated as well.

TABLE OF CONTENTS
EXECUTIVE SUMMARY.............................................................................................................2
INTRODUCTION...........................................................................................................................4
MAIN BODY...................................................................................................................................4
1..............................................................................................................................................4
2..............................................................................................................................................6
3..............................................................................................................................................7
CONCLUSION................................................................................................................................9
REFERENCES..............................................................................................................................10

INTRODUCTION
Energy systems are refereed as the systems that are designed for energy supply services
for the end users. This assignment will be going to highlight the energy performance of different
machineries that are used in production of beer (Brotchie, Newton and Nijkamp, 2017). It will
also include about the identification of cost opportunities and implementation of renewable
technologies to minimise the greenhouse gas emission in profound manner.
Company's Description: It is a small manufacturing company built in the 1970's with 150
employees approximately. Additionally, it is operational in food and beverages sector and has
never undergone any major transformations since its establishment. Heating systems are obsolete
and are fed up with steam and hot water and other machineries are electrically based such as
pumps, compressors, chillers and more.
MAIN BODY
1.
Identification of the most significant energy using processes:
There are several processes in manufacturing of beer that has been classified into three
sections such as mashing (hot process), cold process and packaging. Herein, the most significant
energy using processes includes both mashing and cold process.
Consumption of thermal energy is more during the mashing or hot process, due to the use
of steam and hot water for conducting various treatment processes (Levidow, Skenhall and
Assimacopoulos, 2016). Along with this, the kettle is the largest user of energy on the production
process. It is followed by mashing in which the use of hot water is used at highest levels. This
section related an improvement in energy area has contributed immensely to the energy
consumption in terms of Specific Energy Consumption (SEC).
In context to the cold process, consumption of electrical energy is more because of the
processes of fermentation and filtration. The fermenter is used in combined form with
centrifuging and the filtration procedure is mainly related with the cooling process through
employing coolers. Additionally, this cold section consists of multiple methods such cooling
tanks for maturation method, use of filters for regeneration step etc.
Measurements of energy use:

Estimations for usage of energy should be made to understand the energy efficiency for
transforming one type of energy into another (Lieder and Rashid, 2016). It would assist in the
transitional changes that are required to sustain the resources for longer duration.
In context to beer manufacturing, the kettle has been mostly used single-handedly.
Henceforth, the consumption of energy is achieved by measuring the energies consumed during
the boiling process in order to achieve the evaporation rate at faster levels. Specific heat of
enthalpies and specific energies capacities for consumption of heat losses must be analysed.
Furthermore, the whirlpool is implemented by combining it with the Worth Cooler so that
this cooler recovers maximum hot water to mash in the next batch. This is estimated by
maintaining the pressure and temperature at controlled levels to bring uniformity in mixing the
materials properly.
The power can be calculated as shown in the machineries and thus energy can be
measured by taking the product of power and time (May, Stahl and Taisch 2015). Additionally,
in order to find the efficiency of energy conversion device can be determined by using a
quantitative expression:
Device Efficiency = Useful Energy Output/ Energy Input
Moreover, the energy balances takes place to understand the relationships which is
produced, transformed and consumed during a specific duration. Here, the energy balance
equation is as follows: source + import = export + use + stock variation + losses. This equation
Illustration 1: Schematic Representation of an energy
conversion device
(Source: Efficiency of energy conversion, 2019)

infers as tools that help in analysing the positions of energy consumption and assess the energy
redistribution option.
2.
Main losses
In brewing sector, the main losses occur in the production part especially in the
preliminary, secondary and tertiary sub-sections. Energy is used in almost all forms and in all
sub-sections and processes (Mi, Yu and Wei, 2015). The losses can be outlined to manage the
energy inputs so that efficiency must be controlled and helps in cost-savings, reduce the GHG
emissions with better positioning among the competitors both at local and global marketplaces.
Along with, the main flows of energy with respect to inflow, outflow and exteriors leads towards
the typical efficiencies as mentioned below.
Thermal Efficiency- This is useful for the estimation of generation of steam in the heat
exchanger and certain conditions to know the operational workings of all units.
Combustion Efficiency- It is one of the indicators that helps in determining the ability of burner,
boilers etc. for the absorption of generated heat.
There are many types of losses that occur as follows:
Excess Air: Combustion processes occur that uses potential energy and minimise the overall
efficiency of boilers. Along with this, the losses depend on the burner technology and operational
maintenance.
Convection and Radiation Losses: This takes place again in the boiler vessels, however, these are
lined with insulating materials (Pan, Chang and Chiang, 2015). It also varies on the basis of size,
types and operating variables like temperature and pressure.
Condensate Losses: Hot condensate gets leaked when returning towards the equipment like
boilers, condensers, pumps etc.
Blow-down losses: This takes place in almost all the machineries like milling, mash turn, worth
copper, whirlpool, cooler, fermenter, centrifuge and other processing units that are used in the
production of beer.
Stack gas losses: The stack temperature is defined the measure of heat that is emitted due to
presence of dry flue gases and moisture while conducting the hot water procedure.

3.
Suitability of renewable energy technologies
To bring sustainability factor in this age’s old manufacturing company, it is important to
bring modifications by focusing on the renewable energy technologies. This would offer several
options in cost reductions and laid the foundation of enhancing the energy efficiency. For
example, by applying the Photo-voltaic solar projects in the premises would lead to a more
profitable approach. These technologies must be considered as the currency for renewable
electricity and green power markets. It needs longer duration but is useful in creating a viable
choice to overcome the challenges and barriers posed due to the prevalence of existing traditional
technologies for energy use.
The following are few factors that might promote to adopt the renewable technologies:
 It assists in reduction of all forms of pollution, mainly air pollution as there is use of
compressors, conveyors, cyclone separators etc.
 There are also improvements in the sustainability factor in terms of corporate social
responsibility.
 It also led to eliminate the GHG emissions and release of carbon dioxide with respect to
generation of electricity.
 This would enhance the overall energy efficiency and would improve the shelf life of
machineries for longer duration.

Recommendations
Carbon dioxide (CO2) is one of the important components to be used in the brewing
methodology. It is one of the major by-products of fermentation process and is also useful for
processes such as carbonation, tank blankets, flushing, bottling and others. In this context,
Energy efficiency can be determined by using a CO2 Recovery system with the help of installing
a heat exchanger using pipeline of cold water (Pan, Chang and Chiang, 2015). Traditionally, CO2
gets collected and stored and is used in further processing for the vaporisation process, which is
based on conversion of heat and involves hot water or steam or electric heaters. This also allows
less pure CO2 and might affect the quality parameter of brewing. However, by using CO2 in the
state of liquid in future would be considered as cost-effective. Here, the secondary refrigeration
system can be installed.
Additionally, compressed air is also common in processes where conveyors and mixers
are installed. Thus cost reductions can be made by cutting down on the unnecessary usage of
compressed air. For instance, in bottle-drying process in the packaging section, few equipment
can be made fitted in with on-demand control unit. This would support in supervising the gaps
that might take place between the supply and products. In regard to this, use of solar power
Illustration 2: Cyclic Process for implementing the
Renewable Sources
(Source: Energy Usage, GHG Reduction, Efficiency
and Load Management Manual, 2012)

supply systems can be established in few specific locations of the entire manufacturing unit.
Since solar energy system is an affordable alternative, it would be a more convenient method to
reduce the costs with respect to this organisation’s energy use. This would further improve in
reducing the greenhouse gas emissions and would aid in minimising the use of electrically -
powered machineries like pumps, conveyors and chillers.
CONCLUSION
This assignment has summarized that there are many significant energy using processes
within this company which has been explained and estimated as well. Furthermore, the losses in
terms of the energy-flow, both in and outside this factory have also been evaluated to understand
the requirements needed for energy efficiency. Lastly, the sustainability factor by applying the
renewable energy technologies had been explained along-with suggestions to incorporate it at the
organisational context.
Illustration 3: Outline to plan the Solar Power Supply Systems
(Source: Introduction of Solar PV System on Factory Rooftop ,
2019)

REFERENCES
Books and Journals
Brotchie, J., Newton, P. and Nijkamp, P., 2017. The future of urban form: the impact of new
technology. Routledge.
Levidow, L., Skenhall, S.A. and Assimacopoulos, D., 2016. Process eco-innovation: assessing
meso-level eco-efficiency in industrial water-service systems. Journal of Cleaner
Production, 110, pp.54-65.
Lieder, M. and Rashid, A., 2016. Towards circular economy implementation: a comprehensive
review in context of manufacturing industry. Journal of Cleaner production, 115, pp.36-51.
May, G., Stahl, B. and Taisch, M., 2015. Energy management in production: A novel method to
develop key performance indicators for improving energy efficiency. Applied Energy, 149,
pp.46-61.
Mi, Z.F., Yu, H. and Wei, Y.M., 2015. Potential impacts of industrial structure on energy
consumption and CO2 emission: a case study of Beijing. Journal of Cleaner Production, 103,
pp.455-462.
Pan, S.Y., Chang, E.E. and Chiang, P.C., 2015. Strategies on implementation of waste-to-energy
(WTE) supply chain for circular economy system: a review. Journal of Cleaner Production, 108,
pp.409-421.
Online
Efficiency of energy conversion. 2019. [Pdf]. Available
through:<https://www.ems.psu.edu/~radovic/Chapter4.pdf>.
Introduction of Solar PV System on Factory Rooftop. 2019. [Online]. Available
through:<http://gec.jp/jcm/projects/15pro_tha_04/>.
Energy Usage, GHG Reduction, Efficiency and Load Management Manual. 2012.
[Pdf]. Available
through:<https://www.brewersassociation.org/attachments/0001/1530/
Sustainability_Energy_Manual.pdf>.