ENGT5220: Low Impact Manufacturing - A Report on Industrial Energy

This report examines energy usage in the cake manufacturing process, from raw material acquisition to packaging, focusing on identifying areas of high energy consumption and waste. It explores the potential of incorporating renewable energy sources such as solar, biomass, and wind energy to reduce environmental impact and operational costs. The report also suggests cost-cutting strategies, including regular energy audits, embracing energy-efficient machinery, establishing a supervisory team for energy regulation, and optimizing the HVAC framework. A Sankey diagram illustrates energy flow in a bakery, highlighting waste during the cooling stage. The analysis emphasizes the importance of sustainable development and environmental consciousness in modern manufacturing.

LOW IMPACT MANUFACTURING
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Introduction
Energy is an integral part in the production process. In organizations and production companies
energy is used in the entire production process. The entire product life cycle as from the raw
materials to processing and later disposal is dependent on power (Beneroso & Fidalgo, 2016).
Energy works differently in various stages of production. In some stages, heating is required and
in others cooling to come-up with the end product.
Nevertheless, the entire process should work in a way that energy is well utilized to achieve the
best results while the company also observes environmental needs. Global warming, for instance,
is as a result of depletion of the ozone that is caused by the emission of harmful gases and
chemicals to the atmosphere (Broman & Robèrt, 2017). It is, therefore, quite essential to ensure
that the energy sources are renewable and that the utilization should be of no harm to the
universe. This report focuses on the different energy forms in the production process of cakes
and how to incorporate sustainable sources of energy in the production process.
Sustainable development is the responsibility of every organisation. Therefore, when coming up
with structures of the various departments, it is important to put in place room for the use of
renewable sources of energy. The familiar renewable sources of energy are solar power, biomass,
and wind energy. (Jeswani, Burkinshaw, and Azapagic, 2015) .These sources of energy are also
environmentally friendly and affordable compared to the convention sources of energy like fuel
and firewood. To help in controlling the amount of energy utilized there are some mechanisms
that can be taken up (Broman & Robèrt, 2017). One is the acquisition of machines that are
energy efficient, having in place a team in charge of energy regulation, have in place a workable

plan on starting and stopping of devices and lastly carrying out regular energy audits in all
production phases.
Manufacturing of Cakes.
Commercially cakes are produced in turns of billions daily by baking companies. The primary
raw material or primary ingredient in the preparation of a cake is wheat flour. However, for the
end product to satisfy the needs of its end-users other components such as milk powder, sugar,
fat, eggs, water, flavorings, sodium carbonate, and preservatives (Beneroso & Fidalgo, 2016).
The major machinery used in the production process are commercial mixers, fillers, and ovens.
The systems are automated to ensure standardization of the end product. Cakes produced
commercially in bulk should be of the same size, taste, shape, and appearance (Broman &
Robèrt, 2017). In the production process additives and preservatives are used to attain long shelf
periods. Production of cake is divided into five essential procedures which are namely, receiving
of ingredients, mixing the batter, Filling, Baking and lastly stripping and packaging.
Cake
producti

Acquisition of Wheat Flour
Wheat flour is a product from grounded wheat grains, which is generally the extraction of
endosperms from the grain. The process of extracting wheat flour happens after milling, and in
this process, energy is used substantively (Jeswani, Burkinshaw and Azapagic, 2015). The
process involves two roles which move at the same speeds in a different direction with the
intention of diving the grain and the endosperm most milling machines are either powered by
electricity or diesel engines (Beneroso & Fidalgo, 2016). This process of production is quite
crucial since flour is the main ingredient and also the process is highly demanding when it comes
to energy utilization. It is, therefore, essential to ensure proper energy control in the milling
plants.
Energy utilized in the extraction process can be evaluated by use of a steam chart which will
infuse some mechanisms and procedures that will help in energy regulation (Broman & Robèrt,
2017). More so, the energy used in the milling area can be evaluated by the help of smart energy
applications, Smart meters and thorough machine observing techniques.
Mixing
Mixing is equally an integral part when it comes to the process of manufacturing a cake. Mixing
determines the texture of the cake. Well, the mixed dough will result from tendering and a well
put together cake. Since the use of several ingredients makes cakes, it is entirely necessary to
employ the use of a mixer that will ensure all the elements are well distributed. In this stage of
production energy primarily used by the commercial mixers which can mix a right amount of
dough in a considerably short time (Jeswani, Burkinshaw and Azapagic, 2015). There are three
major types of commercial mixers; planetary mixer, dough mixer, and vertical cutter mixer. The

mixers could either be belt or gear driven. Belt driven tend to be slow but quite cheaper to
manage to gear driven. The gear driven are quite expensive to repair when they break down.
Energy utilization in this procedure can be evaluated by the help of smart meters, machine
observing frameworks and smart energy applications.
Filling the Mould
It is at this juncture that the cake gets its shape. The well-mixed dough is put in containers with
the desired output shape. By the help of automatic fillers, the correct amount of dough is put in
each of the pans. At this stage, energy is mainly utilized by the fillers and conveyors that
facilitate the transportation of the containers to the baking area of production. Just as in the
previous stages the energy in this stage can be evaluated by the help of smart meter, machine
observation framework, and smart energy applications.
Baking
Baking is an integral part and may be the most delicate part when it comes to manufacturing of
cakes. The procedure involves heating. Proper regulation of temperature is quite essential to
achieve the desired product. Cakes bake in ovens, and the ovens tend to vary in respect to the
sizes of the baking entity and sophistication.
Nevertheless in this stage energy is majorly used in the heating of the ovens. The ovens are
helped to maintain the high temperature by the boilers. At this stage of production, energy can
be easily evaluated and monitored by using the smart meters for each of the ovens.

Cooling
In the baking entity, a cooling plant is quite important as they help to keep the cakes in shape
before they fall apart. Cooling is done sometimes immediately or after ten minutes of leaving the
oven depending on the ingredients involved. Cooling further helps to keep the cake in a state
where it can be in slices unlike when it is super-hot. The cooling process greatly reduces the
chances of the cake being stale due to microbiological spoilage.
With improvements made, recycled water is being used to in pipes to cause the cooling effect,
but due to high temperatures, some of the water gets to evaporate to the atmosphere.
The cooling room should be fit with suction tubes with the ability to take away the vapor that is
being released by cakes leaving the oven. The suction tubes ensure that the steam does not
condense in the room as it could lead to adverse effects. The siphons, therefore, help to create a
vacuum. Smart energy meters and applications can be used to measure energy utilization energy
at this stage.
Packaging.
Giving the cake a cover is the last stage of the production process. At this stage, the cakes are
placed into their respective packages. Packaging helps to keep the cake away from pathogens,
informing, marketing and labeling. The packaging material will have the company's name on it,
the ingredients used to make the cake, expiry dates and even contact details. Energy at this stage
is for wrapping the cakes and stacking them in either boxes or crates. To measure the amount of
energy utilized the following can be used; Smart meters, Machine observing frameworks, Smart
fittings/outlets, and Smart energy applications

Sankey Diagram
In a commercial baking facility, it is estimated that 50% of the total energy goes to waste and
this is during the cooling stage of production. Energy is wasted in the sense that it evaporates to
the atmosphere when the ideal plan was to cool off the heat with water that would later be
recycled. (Griffin, Hammond, and Norman, 2016.) Most the energy is however generated in the
oven and boilers while working to maintain high temperatures during baking. The figure below
illustrates the energy flow in Bakery Company.
Renewable Energy
Environmental consciousness is now hitting every production entity. With many voices being
raised to try and salvage the universe by practicing sustainable development it is quite essential
to consider renewable sources of energy. Renewable sources of energy are not only cost-
effective but also friendly to the environment unlike non-renewable that is expensive and
detrimental to the atmosphere. In a bakery set-up, renewable energy can perform in the entire

production process. Biomass, solar, and wind energy have proven to be a force to reckon with
when it comes to sustainable development. (Petek, Glavič, and Kostevšek, 2016.)
Solar Energy.
In the production processes, solar energy can be very useful when it comes to the provision of
energy needed to keep the boilers running. (Beneroso, and Fidalgo, 2016)Fuel is quite expensive
while it will only take a one-off cost to acquire solar panels that will help to heat of water in the
boilers
Biomass.
In the making of cakes, the oven tends to be a great consumer of energy due to the high
temperatures that have to be in regulation in the production process (Griffin, Hammond and
Norman, 2016). Biomass energy would be of great help in this area. The energy is not only
environmentally friendly but also affordable, unlike the petroleum products and electricity.
Wind energy.
The bakery can take advantage of the strong winds and erect a manageable number of wind
turbines to generate energy that can be used to provide lighting in the bakery. Wind energy will
help to reduce operational costs by a good percentage and thus an opportunity to expand the
operations. The same energy could also be helpful for the coolant which is an essential part of
the cake production process (Jeswani, Burkinshaw and Azapagic, 2015).

Cost Cutting strategies in energy utilization.
Conducting regular Energy Audits
The company needs to ensure that it carries out proper departmental energy use. The audit could
be done by held by internally or out-source auditors. The examination will help to inform the
company how good or bad the energy was performing compared to the production output. The
audit would further improve the organization to know where to effect energy saving techniques
to save on the cost.
I am embracing innovations.
New machinery in the market is made to work efficiently. Comparing machinery from way back,
the more the years go by, the less energy consuming machinery are being produced. The
company should, therefore, work towards the acquisition of machinery that is latest and effective
in the production cost. The company can for instance ditch the old boilers that relied on firewood
to keep afloat.
Having in place a supervisory team,
Responsibility should be given to an able team to supervise how energy is used in the various
departments. Every department should have a supervisor whose role will be to ensure that power

works well in his/her area of operation. The team will further communicate with the management
on their findings which will inform the decisions made towards saving energy.
Organized operation of machines.
Machines should have strict schedules on their shut-down and start-up. The programs will help
to reduce the amount of energy consumed during the periods when production is in not at its
peak. The schedule should be adhered to by the machine operators for this to work.
Review of the HVAC Framework.
HVAC role is to ensure that air quality in the operation areas is well maintained. For best results
then the systems should be put under scrutiny after certain periods. Regular reviews of the
performance of the frameworks will inform on what should be rectified to achieve the best
output. The results of the surveys will give directions on what should be acquired to support the
existing frameworks. All the HVAC are in charge of keeping up air quality and the solace of the
generation office (El Sheikha, 2015).

References
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