Food Processing

Presence of high harmonic distortion, iTDD exceeding standard limit specified by IEEE 519

Recurrent failure of power electronics/expensive process automation equipment, frequent failure of capacitor banks and malfunctioning of control circuits

Production down-time due to disruption in operation of continuous machines

Inflated monthly electricity bills due to low power factor (true)

Loss of input material in case of food industry, loss of machinery in case of plastic industry

Low efficiency of motors

Insufficient cooling due to

Heat transfer due to inadequate insulation of roof

Heat transfer due to lower quality of window panes

Overall heating in the facility

Fresh Air Supply-  Insufficient
–  Energetically inefficient without Heat Recovery units

Insufficient cooling

Excessive humidity

Odor & mould

Spoilage of food stuff
Lack of worker efficiency

Lack of re-usable water

High operating cost due to higher consumption of electricity by Halogens and conventional flood lights/hi-bays

Higher replacement costs due to shorter lifespan

High thermal impact on cooling

High Humidity

High temperatures

Odor-Food/smoke/mould

Bacteria and fungus develop in high temperatures and humidity

Food spoilage/wastage due to bacteria and fungus

Dust/VOC's/CO2

High level of harmonic distortion is the main reason of expensive cards failure

7Bar Air Compressor, 40Bar Air Compressor, Refrigeration Panel, Juice Line identified as major non-linear loads – can be driven by AC or DC drives

High harmonics resulting in low true power factor

High harmonic distortion generated by large chiller units, lifts/elevators and lighting loads

5th & 7th Harmonics, resonances and transients leading to irrepairable damage to the capacitor banks

Fluctuating load profile and sudden reactive jerks of lifts/elevators

Over voltage due to positive tap change policy of utilities

Old technology of capacitor banks which are contactor switching and not suitable for today's loads

Higher ambient temperatures lead to significant de-rating of motors and drives

Lack of sufficient air flows lead to low dissipation of heat leading to de-rating of motors

 lack of insulation of boilers & distribution pipes

 Insufficient thermal insulation of windows & doors

Over burden on HVAC

Corrugated steel roof leading to massive heat transfer

Incorrect choice  of the chiller plant- this may be due to incorrect sizing or incorrect technology

Poor Maintenance of chiller plants

High Humidity

Incorrect configuration

Imbalance in air pressure

High ambient temperature

Use of hydrazine which is a toxin

Old technology of conventional lightings

Inadequate light output

Significant light depreciation within 6-9 months of installation

Lack of dehumidification

Lack of cooling/ insulation

Lack of indoor air treatment

Excess use of solvents

Lack of indoor air filtration

Active Harmonic Filter at major nonlinear loads

Dynamic power factor correction with detuned filter reactor with ZERO crossing

Hybrid Filter suitable when power factor is low

Voltage optimizers

Reduction of heat with use of pre-cooling mechanisms to bring down temperatures where motor performance can be optimsed

Use of high CFM fans to create air low and improve performance

Special coating which arrests heat transfer up to 70%.

Air curtains and open space cooling

Arresting leakage of hot air from doors and delivery sections

Cool roof coatings

Heat Recovery Unit

Yearly audit and maintenance of HVAC and proper configuration of chiller plant.

Refurbish existing Heat Recovery units by chemical cleaning of Heat Wheels, Enthalpy Wheel or Desiccant Wheel

Additional upgrade of  HRU with Horse Shoe Heat Pipe or Desiccant Dehumidification

Consider advance air distribution technologies such as Bosch Clemotion or Composite air ducts.

Chiller replacement for highest energy savings and lowest cost of ownership – Heat Pump
-Water cooled chiller
-Invertor based chiller

Shading of chiller plant and Wet wall

Replace Hydrazine with Polyamines

Replacement by LED with following specs:
-160 lumens/watt
-less than 10% depreciation in light output over the expected life of 5 years
– TL-21 certified
– LM 79 and LM-80 compliant

Heat Recovery Unit

Horse Shoe Heat pipe

Desiccant dehumidification

Indoor air purification

HEPA and Carbon filters

Oxygen concentrators to improve air quality

Total current harmonic distortion maintained within limits specified as per IEEE standard (iTDD <8%)

Significant savings (both tangible and intangible) through elimination of failures

Improved supply voltage by reduced harmonic distortion

True power factor maintained close to unity

Significant savings through reduction in monthly electricity bills

Lower maintenance cost due to lower disruption

Uninterrupted operation of continuous process machines

Higher performance of the motor will lead to higher output

Less heating of motor will lead to significant savings in energy costs.

HVAC is no more over burdened

Wellbeing

Prevention of spoilage in the food industry due to adequate cooling

Lower energy cost

Lower diesel consumption

Lower cost of utilities (DEWA bills)

Adequate cooling

Improved life of chiller plant

Less downtime or break downs thereby savings in maintenance costs

Overall well being

Safer and cost effective

Better light output
Well being
Reduction in heat load on HVAC
70-80% reduction in electricity bills
Significant reduction in maintenance costs due to longer asset life

Wellbeing

Less maintenance problems

Lower wastage and spoilage of food stuff

Better air quality