Case Study #1: Energy Study for Bakeries in Jordan

Case Study #1: Energy Study for Bakeries in Jordan

Introduction:

Cambridge Engineering conducted an energy audit study for a multi-flour bakery in Jordan, aiming to assess energy and water consumption and identify opportunities for cost savings. The study analyzed the energy and water usage for each ton of flour produced and outlined recommendations to optimize energy efficiency. This case study highlights the findings, conclusions, and implemented measures that resulted in significant cost reductions for the bakery.

Energy and Water Consumption Analysis:

During the energy audit, Cambridge Engineering analyzed the energy and water consumption associated with each ton of flour produced. The study revealed the following consumption rates and costs:

• 81 liters of LPG, costing $53.
• 84 liters of diesel, costing $84.
• 155 kWh of electricity, costing $15.
• 13 cubic meters of water, costing $46.

The average energy consumption for each ton of flour amounted to $198. These figures provided valuable insights into the bakery's energy and water consumption patterns, highlighting the areas with the most significant cost implications.

Energy Audit Recommendations:

Based on the energy audit analysis, Cambridge Engineering recommended several measures to reduce energy costs. The major recommendations included:

1. Switching from Diesel to LPG:
2. The study demonstrated that using LPG instead of diesel for ovens resulted in a cost-saving of approximately 22% of the diesel cost. Cambridge Engineering advised the bakery to make this transition, enabling them to significantly reduce their energy expenses.
3. Upgrading Oven Burners:
4. Cambridge Engineering recommended replacing the existing oven burners with long-head burners to improve heat distribution and achieve homogenized heat inside the oven. This optimization measure enhanced energy efficiency and baking performance, resulting in further cost savings.
5. Air Compressor Control:
6. By installing an air compressor controller, Cambridge Engineering aimed to minimize the working hours of the compressor. This control mechanism ensured that the compressor operated only when necessary, reducing unnecessary energy consumption and subsequently lowering electricity costs.
7. Utilizing Specialized Bread Fermentation Rooms:
8. As the bakery relied on fermentation processes to provide the necessary heat and humid environment continuously, it consumed a considerable amount of electricity. To address this, Cambridge Engineering recommended using specially manufactured bread fermentation rooms instead of hand-made ones. These specialized rooms were designed to conserve energy, providing optimal fermentation conditions while minimizing electricity usage.

Results and Cost Savings:

Following the implementation of Cambridge Engineering's energy management opportunities (EMO), the bakery experienced significant cost reductions. The energy and water cost per ton of flour decreased from $198 to $166, resulting in overall savings of 16%.

Conclusion:

Cambridge Engineering's energy audit and subsequent implementation of energy management opportunities proved highly effective for the multi-flour bakery in Jordan. By identifying specific areas of energy and water consumption and providing tailored recommendations, the bakery achieved substantial cost savings. Through measures such as switching fuels, upgrading equipment, and optimizing operational practices, the bakery significantly enhanced energy efficiency and reduced its environmental impact. Cambridge Engineering's expertise and commitment to energy management have enabled businesses to achieve sustainable and cost-effective operations.