Effective Reduction in Utility Cost in A Beverage Plant

Abstract

This project. is about in-depth focus on equipment power analysis and effective reduction in Utility and Quality Cost. A Value Stream Map has been developed and analyzed to identify critical focus areas in Utilities, Process and Line. The most significant key input variables have been identified and those are Boiler, Old-Utilities, New-Utilities, Process Area & Cooling Towers, which are prioritized based upon their relationship with the key output metric. Key input, process, and output metrics have been identified. As a part of Root cause analysis, Power consumption is high due to Running of 2 compressors, yolk chiller, raw water pump, cooling tower pumps & fan and new refrigeration for cooling tower pump. Potential implementation solutions are to be developed, evaluated, and optimized based upon their effectiveness impacting the key output, robustness to variation and ease of implementation. The final improvement solution has been incorporated into the process organization and the improvement gains of 3 – 25 KWH are being expected.