ENERGY AUDIT UNCOVERS IMPRESSIVE EFFICIENCY POTENTIAL IN SPRAY DRYING LINE

Following the design and integration of a state-of-the-art spray drying line in 2015, a longstanding customer, a major German dairy, came to GEA with the ambition to significantly reduce the line’s CO₂ emissions. Thermal energy generated by the burning of fossil fuels results in levels of CO₂ emissions that are excessive today – particularly to those with environmental responsibility at the heart of their operations. As a result, GEA’s energy experts were engaged to carry out a holistic energy audit in order to recommend an effective roadmap to savings in the short, medium and long terms.

The challenge: highlight action areas in spray drying operations to reduce CO₂ emissions

Spray drying operations back in 2015 were heavily focused on production efficiency and quality. Fuel prices were lower, and while the environmental impact of capital equipment was a factor, it was not as high a priority as it is today. The challenge for GEA experts was to interrogate the mechanical makeup of a line already optimized for maximum throughput, and to outline investment pathways that would reduce thermal energy usage and also costs at an attractive ROI – at the same time maintaining the same levels of productivity and quality. 

The solution: a holistic, whole- of line energy audit leveraging decades of expertise

Following a site visit as part of the data acquisition process, GEAs experts created a bespoke digital model of the line with a focus on the specific energy requirements of the equipment – both individually and as a complete integrated production line. There followed a phase of energy targeting, which gives specific insight into potential areas where savings can be made and the root causes of any inefficiencies. 

Leveraging GEA’s decades of process knowledge and technical expertise, as well as advanced in-house competencies in energy analysis, accurate benchmarking data taken from actual GEA installations was used to determine how efficiently the line and its equipment should be operating without blocking and cannibalizing energy streams. With this in place, accurate calculations were made in terms of both CO₂ reductions and cost savings based on the identification of six individual solutions – ranging from those that could be implemented quickly with relatively low investment, to those that would require a longer term strategy. 
This approach is a perfect example of GEA Add Better Consulting, which is designed to keep business robust while pursuing sustainability goals.

The results: an actionable roadmap to energy efficient, profitable spray drying 

As outlined, a total of six actionable solutions were identified as a result of the holistic energy audit of the customer’s line – each carrying its own investment level and associated benefits.

At one end of the spectrum, something as simple as adjusting a valve setting could have an immediate and ongoing impact with close to zero outlay, whereas at the other, investing in GEA’s first-of-its-kind high-temperature heat pump system, the GEA AddCool®, would likely require greater consideration but would deliver greater benefits.

Across the six solutions identified – the customer was presented with a total potential saving of 8,400 tons of CO₂ per year, equating to savings of over €1.8M Euros in operating expenditures across the same period with zero loss of production capacity or product quality.

The future: tangible pathways to a net zero future in spray drying operations

Whilst incremental improvements can deliver gains, the ability to work with a single source supplier such as GEA – with in depth, in-house knowledge and technical expertise across the entire process chain – enables customers to achieve the true efficiency gains that only come with a strategic, holistic approach. Further, GEA’s commitment to developing close, collaborative relationships empowers its experts to engineer with purpose -driving innovation and the development of future-focused, sustainable technologies for its customers.