32 n ENERGY EFFICIENCY September 2024 www.drivesncontrols.com Automating feed mills saves energy and cuts costs From pulp and paper, to flour and grain, the milling industry has seen a shift in priorities. Instead of focussing solely on making products, there is now an increasing emphasis on optimising operations, minimising environmental impact and cutting costs. This shift reflects the industry’s effort to navigate the upswing in energy prices and to address the climate crisis. Take, for example, ADM, one of the world’s largest nutrition companies. Its Strive 35 initiative aims to cut greenhouse gas emissions by 25%, energy intensity by 15%, water intensity by 10%, as well as achieving a 90% landfill diversion rate, all by 2035. Energy plays a significant role in determining the costs related to producing feed for poultry and livestock. A typical feed mill producing 250,000 tonnes of feed per year can expect to spend as much as £750,000 a year on energy. There are numerous strategies to enhance efficiency, including investing in energyefficient equipment such as motors, drives and compressors, and improving maintenance practices. However, turning to automation is one of the most effective approaches. Feeding systems transport raw materials such as grains and seeds into mills, where they are ground into smaller particles or powders. To process a variety of animal products, mill feeding systems need regular speed adjustment. Automating a feed plant allows manufacturers to reduce margins for error across their processing and packaging processes. Mills that introduce automation systems, capable of varying feed speeds, not only cut energy use but also enhance sustainability practices. By contrast, feeding systems that rely on manual labour can struggle to strike the right balance when adjusting feeder speeds. If the speed is too slow, this can lead to extended shifts and wasted energy and, if the rate is too fast, quality can suffer. Implementing a consistently efficient feeding process, driven by automation, enables feed manufacturers to improve throughput in every shift and to reduce running times. Furthermore, operating a system at its peak performance, not only saves time but also allows facilities managers to focus their attention on other crucial aspects of manufacturing such as compliance with safety regulations and coordination with suppliers and distributors. Cutting costs Achieving energy-efficient milling translates into substantial cost savings. By curbing energy consumption, manufacturers can trim their operating costs, thus enhancing their financial performance. Automated speed control optimises energy use without compromising operational efficiency. This results in improved product quality through optimal grinding, and a reduction in plant running hours, further contributing to sustainable and cost-effective milling practices. Bespoke systems can use control algorithms and precision engineering to modulate feed mill speeds. This ensures a fine balance between energy savings and preserving feed quality and consistency. Beyond immediate cost savings, the impact of energy-efficient milling extends to the maintenance and the longevity of milling equipment. Notably, these systems reduce wear-and-tear and offer more controlled operating conditions, ultimately helping to extend equipment lifecycles and reducing the need for maintenance. For example, consider Kerry Agribusiness, an Irish operation that produces 1.2 billion litres of milk annually from 3,000 family-run farms. It has implemented an advanced VSD technology which controls motor speeds precisely to streamline the feed milling process, resulting in a 29% increase in throughput. The system (supplied by Technidrive) has replaced traditional manual controls with a software interface that supports remote monitoring and control. Eliminating the need for trial-and-error adjustments, operators gain real-time insights into milling operations. Enhanced by a smart algorithm, the system adjusts the feeder speed dynamically, striking a balance between energy savings and operational efficiency. The benefits are twofold. First, it reduces unnecessary energy consumption by ensuring precise calibration of the milling process, thus reducing electricity consumption and helping to extend equipment lifespans. Second, the system improves the milling efficiency significantly, resulting in increased throughput. Streamlined operations, combined with remote monitoring capabilities, not only cut downtime but also allow prompt adjustments, leading to a more sustainable and costeffective approach for mill operators. n Controlling the speed of machines that feed products into mills can unlock energy efficiencies and lead to substantial cost savings. Gary Kernaghan, automation manager at the systems integrator Technidrive, explores how automation can change the economics of such mills. Milling plants are turning to advanced automation to help reduce their energy costs and to boost productivity
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