A Perfect Fit
India's dairy industry is booming - but also needs a lot of energy. A connected and integrated solution provides the remedy.
India’s dairy industry has grown unabated since the mid-1970s. At over 150 million metric tons per year, the country has grown to become the largest milk producer in the world. However, given that its energy has, to date, been primarily generated using coal-fired power plants, India is currently still the world’s third-largest emitter of CO₂. This is just one of the reasons why the country is appealing to its companies to invest in efficient technologies and sustainable solutions to lower energy consumption in the long term.
Customized Energy Solution
The “Sri Mahalakshmi Dairy”, known in India for its Aroma brand of milk products, aims to set a good example in the industry and forge ahead with energy-efficient production. With an annual production volume of 200,000 liters of milk, the company is currently one of the largest private dairy operations in India. The dairy has placed its trust in the problem-solving expertise of Bosch Energy and Building Solutions to keep operations running sustainably. The experts from our team in India studied the industry’s requirements in detail and developed an Integrated Heating and Cooling Solution for dairies,
which is currently being implemented at the Sri Mahalakshmi Dairy facility in the city of Coimbatore in southern India. The processes in dairies utilize energy for both heating and cooling. While heating processes employ steam generators, chillers are installed to meet cooling requirements. The core of the new solution’s performance lies in how demand from the dairy processes and supply of energy from the heating systems are integrated and synchronized to achieve substantial energy savings.
less energy is consumed by the dairy thanks to the integrated solution.
In India, dairy products such as butter lard called ghee or yogurt (Lassi) play an important role; not least because it serves as a protein source for the meatless living part of the population. According to the Food and Agriculture Organization of the United Nations, the country is with around 72 million
tonnes of milk the third largest producer in the world after the EU and USA. If one adds the quantity of buffalo milk produced as usual in Asian countries, India is in first place with an annual production of 155,000 tons.
Integrated solution from a single source
Integrated Energy Concept
Bosch’s solution captures heat from existing utilities, such as the boiler and heat pumps, or waste heat. The heat energy is then stored in a stratified storage tank for distribution based on process requirement. Instead of steam, many high-temperature processes now use pressurized hot water. “This allows us to minimize energy consumption while simultaneously cutting energy losses caused by the condensate lines,” says Venugopalan CM, Head of Bosch Energy and Building Solutions in India. “We even make use of the temperature of the used cleaning water to heat up the water for the next cleaning procedure, which also helps to conserve water” he adds.
Use of heat pumps
The energy from the recuperator is used in the milk and curd pasteurization processes, in the drying room and in the dehydrator for production of milk powder. Another building block of the solution is the extensive employment of heat pumps which are used for heating purposes with temperatures less than 75°C and also help save electricity for cooling processes.
An energy management platform is used to ensure that the complete potential that the solution offers is exploited to maximize efficiency. It captures consumption data and visualizes it in a meaningful manner. “The platform helps us identify which processes generate excess heat or cooling, and where, in turn, this heat and cold can be used. This allows us to manage requirements and demand efficiently,” says solution expert Karthikeyan N S. To enable precise recording of energy consumption, Karthikeyan and his team installed temperature and pressure sensors, as well as energy meters, at various points in the system, such as the stratified storage tank and the milk pasteurization facility. Thanks to the energy management system, these data are now available directly on the portal.
Recognize and use potential
For the Bosch experts and their customers, the data provides a basis for tapping further potential for efficiency. The connected solution also has a preventive function. As soon as critical values are detected that could affect systems processes, the platform issues an alarm – the service team can then respond immediately, to maintain the systems at the required efficiency levels.
We do not simply reduce the annual costs for our customers, but also protect the environment.
“Thanks to the integrated solution, the dairy’s energy consumption has been decreased by 14%. This not only reduces the annual costs for our customers, but also helps protect the environment; at present, we’re able to save 450 metric tons of environmentally harmful CO₂ annually,” says Venugopalan CM. The scope of delivery included the planning, detailed engineering, installation and calibration to ensure optimal operation. “The most important thing when working on a project like this is having an experienced partner at your side who combines and integrates all of the technical components in a complete system to ensure full functionality. This makes it possible to achieve the optimum in terms of performance and service life,” as Venugopalan C M concludes.