Reducing GHG emissions and improving cost effectiveness via energy efficiency enhancements: A case study in a biscuit industry

Copyright © 2021 The Author(s). As the new climate change driven regulations are brought into the force and energy prices and sustainability awareness increased, many companies are looking for the most efficient way to reduce their energy consumption and greenhouse gas (GHG) emissions. In this context, the food industry as one of the main energy consumers within the industry sector plays a significant role. This paper analyses the current energy consumption in a biscuit manufacturing company and considers a number of possible solutions for the energy efficiency improvements. The company uses modern and automated production processes and has signed a Climate Change Agreement. The experimental part involves identification of the energy users, as well as analysis of the energy bills, operation times, production schedule and on-site measurements of energy consumption. The opportunities for energy efficiency improvements, GHG emissions and costs reduction are investigated and additional information about the investments and payback period of the proposed improvements discussed. A number of opportunities for improvement are identified within the production area with a potential savings of 23%, which corresponds to EUR 40,534.00 and 190 tCO2, annually. It was found that the significant savings could be achieved by better managing the production lines and reducing operational hours from equipment, with no impact on productivity and no capital investment required. Further savings can be achieved through technical improvements requiring capital investments. All those improvements and savings make a significant contribution in accomplishing environmental targets set out by the FDF1 agreement.Innovate, UK (project number 9484)