Energy audit of a meat processing plant

Abstract

The study has come up with energy saving solutions for different sections or equipment of a meat processing plant in Botswana. Much of the old original equipment at the abattoir is still in place and there exists an opportunity to lower energy consumption through the adoption of modern energy saving measures. Modern engineering instruments were used to determine the efficiencies of various manufacturing equipment so that cost-benefit analysis could be carried out. The use of premium efficient motors and variable speed drives can significantly lower motor power use. 25 motors were analysed and it was ascertained that the adoption of premium motors could save P71702 annually with payback periods of less than 3 years. An ultrasonic detector pointed out leaks in the compressed air system however a leakage test estimated that 35% of the air in the system is lost to leaks while about P11000 could be saved annually by reducing the discharge pressure. The water and energy consumption figures are benchmarked against those from modern plants. It was found that the plant’s electricity and water consumption are much higher compared to modern plants. Software analysis shows that insulating certain surfaces in the plant’s thermal systems can be economically viable. Installation of efficient sterilizers could save about P780000 annually in water and coal. Retrofitting light fixtures was found to have a potential to save about P66000 in electricity costs annually. Maintenance practices were scrutinised as adequate maintenance could lead to energy savings, lower overall maintenance costs and higher machine availability.