Feed International - January/February 2010

Energy savings not a dream

French feed manufacturers cut energy costs 20% over the past two decades with opportunities to

Engines offer potential savings

“From 1985 to 2007, the average reduction in consumption in French feed plants was 18% (from 75 k Wh/t to 61 k Wh/t) and 45% in cost (euro constant), mainly because of lower heat costs,” says François Lucas, Tecaliman’s spokesperson for energy.

Naturally, the reduction was more important during the first 12 years than the last 10. For the future, François Lucas sees improving potential in engine (90% of electrical costs) and in the granulation/cooling post as they represent 60-80% of all energy costs.

gain more.

Le Gouessant is a Brittany feed manufacturer that has boosted its bottom line by slashing energy costs. The cost of energy for the company’s six feed plants, including one dedicated to fish feed, reached 3. 5 million euros last year, a cost spiral that propelled the company into action.

changed its compressed air production and distribution system as it had so many leaks. And the company installed a synchronous engine on one of its hammer mills.

With the new engine, “It is much smaller and lighter, 450 kg to compare with 1. 5 metric tons, with less energy to (move),

From 1985 to 2007, the average reduction
in consumption in French feed plants
was 18% and 45% in cost.

“We decided on a long-term plan to cut energy costs, using the technical expertise of the people in charge of plants, staff management, maintenance and energy itself,” says Daniel Cornier, who leads the energy strategy, started 18 months ago.

quicker speed change, start and stop,”
says Cornier. “We cut the working time
with no cost because this engine starts
quickly. We do the same for the fan on the
horizontal cooling and save 20% of energy
used there, because this new engine does
not use a driving belt.”
In feed and food processing, the main
part of motors which develop more than
10 k W use a fixed speed. About 10-12%
are equipped with a dimmer switch.

What research revealed

“Research showed that one of the first actions to focus on was the way compressed air was utilised,” says Cornier. For example, one plant was using 350 Wh/ Nm3 (hydrochloric acid vapour removal efficiency) in compressed air, while another used only 140 Wh/Nm3.

Le Gouessant worked on measurement, management and equipment and

How to cut costs

New motors are a major way for plants to cut energy use, the French feed research centre Tecaliman says. “The research centre dealing with energy optimisation (RTM) focuses on the use of electric motors for processing or ventilation, compressed air, pumping or cooling,” says François Lucas Tecaliman’s energy spokesman.

Optimisation of equipment

“Equipment optimisation is the first step in saving,” says Lucas. For example, a synchronous engine sees output reduced as soon as it’s at only 50% capacity. A synchronous motor then adapts more easily and is of help for frequent starts. But a dimmer switch is of no use if the line is not equipped and well monitored.