Analysis of Industrial Energy Systems: ENGT5220 Module Report

This report provides a comprehensive analysis of industrial energy systems, specifically within the context of cheese production. It delves into the significant energy devices utilized, such as boilers, evaporators, and dryers, highlighting their role in various stages of the manufacturing process. The report emphasizes the importance of energy conversion and the potential for energy loss, advocating for efficient energy management practices. It also explores the energy requirements for different types of cheese, including UF-Feta, cheddar, and ras cheese, and illustrates the manufacturing processes with diagrams. Furthermore, the report discusses the potential of renewable energy technologies and sustainable practices, recommending the adoption of renewable energy sources and energy-efficient techniques to minimize environmental impact and enhance the economic viability of the cheese industry. The report underscores the significance of monitoring and managing energy consumption to achieve both environmental and economic benefits.

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Table of Contents
Significant energy devices used in production...........................................................................1
Conversion of energy.................................................................................................................2
Renewable energy technologies.................................................................................................7
References..................................................................................................................................9
Appendix..................................................................................................................................10

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Significant energy devices used in production
Energy is one of the substantial resources in production of any products and cheese is
one of such product where the without the use of energy it is not possible to carry on the
manufacturing activities. The essential ingredients of cheese are milk, and the processing of
milk utilizes a large amount of energy (Philipp et al. 2016). Energy is required in various
processes such as homogenization, pasteurization, and cooling. In manufacturing of cheese,
both electrical and thermal energy are essential; however, it is assumed that thermal energy is
more consumptive in the entire production process. Energy requirement differs for each
cheese product such as to manufacture white cheese and hard cheese the amount of energy
requirement will be different. In a cheese industry, significant operations are performed by
using advanced technology such as boiler, pasteurizers, evaporators, connecting pipelines,
cooking fats, dryers, and many more other processing devices that require adequate energy to
carry out the manufacturing activity.
Boiler is essential in dairy industry. To convert the raw milk into a high-quality dairy
product, an efficient steam boiler is required. Raw milk cannot be used directly for preparing
various cheese products, the raw milk gas to undergo a temporary heating process by which
all pathogens and other impurities are killed to form multiples dairy products such as cheese,
butter, and many more. Steam boiler is an essential tool for heating processes as it can be
used for specific time frames to make sure that milk is heated adequately for further
processing (Light 2014). Boiler is used to sterilize the surfaces and handling all the materials
to prevent the growth of harmful bacteria. If boilers are efficiently used, then they produce
steam quickly and that too, with less fuel and water waste. By managing, the entire
functioning of steam boiler energy can be saved largely.

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Evaporator’s processor refers to devices used to the conversion of liquid to vapour. To
remove volatile solvent from a solution or to dilutes slurry by vaporization process the
evaporators are used. In dairy industry evaporation method is used to remove moisture from
milk under a vacuum with boiling and this entire process requires a lot of energy
consumption. Falling film evaporators, circulation/ vertical evaporators, and horizontal tubes
evaporators are most commonly used in any cheese industry.
Dryers and vacuum concentration are essential methods for water removal and for
stabilizing the dairy products; thus, they can be safely and efficiently consumed by multiples
customers (Erbay et al. 2015). The dehydration process of dairy products requires a
significant amount of energy consumption. By using energy, the vacuum evaporation
removes water fraction and then transform a low viscosity liquid into relatively highly
viscous concentrate. The spraying dryer turns this concentrate into powder by spraying small
droplets into the flow a hot air.
Conversion of energy
The process of transformation of energy from one form to another result in loss of
energy, and it entirely depends on the management of the company to ensure that there is
minimal loss of power. Efficiently utilizing the energy consumption process is essential for
cheese industries as the entire manufacturing process of cheese products needs energy at each
level of production. Thermal energy assumes to be a significant energy component during
cheese manufacture. Various activities such as pasteurization, operating the filtration system,
cooling, and pressing machine consumes electrical power. The production of cheese required
the consumption of electricity in large scale.

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In every industry, there must be accounting done to maintain proper records relating
to the consumption of energy and its losses. Even estimation must be done relating to water
consumption during the processing (Mohamed 2015). Specific products can be taken into
consideration to measure the energy consumption process and its losses. These products are
UF- Feta like cheese, cheddar, ras, and many more (Rohde and Rohde Brothers Inc 2018).
Milk is considered one of the significant ingredients in the manufacturing of these products.
The UF-Feta, like cheese, used the ultrafiltration technique that is a new technique to make
soft white cheese. The finished product of cheese obtained from this method is homogenized
and filled in tetra bags so that the food can be used for an extended period. The
manufacturing cost of cheddar cheese is quite high, and due to this reason, it has a high price
in the market. The production of ras cheese is similar to the manufacturing process of cheddar
cheese; however, if the technique is modified, then the cost of production can be reduced.
The methodology of the manufacturing process is shown below in Fig (1), Fig (2), Fig (3) of
the cheese products.

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Fig (1) Illustration of UF-Feta like cheese production

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Fig (2) Cheddar cheese
manufacturing process
Fig (3) Ras cheese
production process
In a general view, the
production of cheddar cheese and
ras cheese required more energy
consumption is used in ripening of

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the product as compared to UF-Feta like cheese. As thermal energy is used primarily in the
production process of cheese products, it is evident that highest loss of power will take place
in the thermal energy.
Figure showing energy consumption in the cheese industry
The production of cheese includes activities such as airing, maturation, and storing,
and these activities need to be controlled under specific temperature and humidity. Even the
company needs to ensure that there are no unnecessary inventories as it will lead to extra
energy consumption. The refrigerated chambers used for the storing of cheese consumed a
massive amount of energy, and it is the management responsibility to ensure that there is less
wastage of energy.

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Renewable energy technologies
Sustainable renewable energy methods require a sustainable supply of clean and
affordable renewable energy sources that will be beneficial for the company as well as
society (Finnegan et al. 2018). Various wastes from the industry can be converted to useful
energy resources such as biohydrogen, biogas, and many more by availing waste-to-energy
technologies.
The management must efficiently manage multiples energy utilizing processes that
are used in the manufacturing of cheese. Sustainable renewable energy technologies must be
maintained by the industry to maintain a profitable situation for the company (Rugele et al.
2015). The sector must follow proper use of furnace insulation and maintenance techniques.
The efficiency of energy must be improved to lower the oxygen levels in exhaust gases so
that the heat level raises (Fox et al. 2017). A modifies backpressure steam turbine must be
used in the manufacturing process.

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References
Erbay, Z., Koca, N., Kaymak-Ertekin, F. and Ucuncu, M., 2015. Optimization of spray
drying process in cheese powder production. Food and bioproducts processing, 93, pp.156-
165.
Finnegan, W., Yan, M., Holden, N.M. and Goggins, J., 2018. A review of environmental life
cycle assessment studies examining cheese production. The International Journal of Life
Cycle Assessment, 23(9), pp.1773-1787.
Fox, P.F., Guinee, T.P., Cogan, T.M. and McSweeney, P.L., 2017. Fundamentals of cheese
science (pp. 185-229). New York: Springer.
Light, K., 2014. Farmers in Vermont's Artisanal Cheese Industry: Examining what Influences
Dairy Farm Management.
Mohamed, A.G., 2015. Low-fat cheese: A modern demand. Int. J. Dairy Sci, 10, pp.249-265.
Philipp, M., Schumm, G.M., Peesel, R.H., Walmsley, T.G., Atkins, M.J. and Hesselbach, J.,
2016. Optimal energy supply structures for industrial sites in different countries considering
energy transitions: A cheese factory case study.
Rohde, M.E., Rohde Brothers Inc, 2018. Energy-efficient apparatus for making cheese. U.S.
Patent 10,021,891.

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Rugele, K., Bumanis, G., Mezule, L., Juhna, T. and Bajare, D., 2015. Application of
industrial wastes in renewable energy production. Agronomy Research, 13(2), pp.526-532.
Appendix
Image of steam boiler in cheese production

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Image of evaporator