MEAT PROCESSING

Increase production and save energy

Find out how Crowley Carbon can use software and engineering expertise to help increase your capacity and save you money on you energy bill.

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Increase in process efficiency

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Saving in energy consumption

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Real-time visibility of saving opportunities

Refrigeration in Meat Processing

CHALLENGE

Refrigeration can be up to 70% of energy costs

And, it can sometimes feel that Fridge power consumption can be an uncontrolled cost centre too.  Power consumption can vary significantly with weather conditions, production changes, operator and maintenance input (or lack of same!).

The following are some of the issues which we typically see which are causing excessive energy consumption in meat factory refrigeration plants:

  • Using simple energy KPI’s (kWh’s per tonne or kWh’s per head of cattle killed) that do not highlight either energy losses OR savings opportunities during dynamic conditions i.e. weather changes, production increases/decreases or product mix changes 
  • No real understanding of how production changes (product mix changes for example) can drive energy consumption changes
  • Insufficient automation in place or;
  • Automation switched off (maybe initially only temporarily) and plants running in manual
  • Plants do not dynamically adapt to changing weather and to production conditions
  • Plant equipment consuming more power and water than design due to lack of maintenance or incorrect installation

THE SOLUTION

Build digital models and feed them live data

Modelling of individual refrigeration system components so now you have an accurate prediction of the overall refrigeration plant performance you will start to see deviations between the actual and predicted (over time) as the plant conditions start to change i.e.

  • Condensers foul
  • Air ingress occurs on the low temperature side 
  • Compressors degrade 
  • Oil carries over to evaporators
  • Automation switched off and compressor sequencing not as it should be 

 

 

The solution lets you:

Build Predictive Models

Get insights by building individual models of each of the major components i.e. the compressors and condensers.

Identify what drives overall plant energy consumption

A  robust method of tracking energy consumption is to use statistical analysis tools.

Overlay live data onto models

Bring those models to life i.e. feed them with live pressure, temperature data from the plant and calculate dynamically and continuously the predicted plant performance – and compare it to the actual.

The Business Benefits

Real, measurable savings

Our solutions have been delpoyed countless times to delvier real measureable sagings to customers

The solution gives you:

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Rapid Delivery

Our 12-week proof of value model delivers savings from day 1

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Visibility

We give you greater visibiity of you operating plant than ever before

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15%+ energy savings

We deliver real savings through optimisations

Guaranteed and Insured

We don’t leave it to chance, we guarantee the outcomes