Alapala Makina is the oldest and main company of the Alapala Group. It is one of the world’s largest companies in the milling technology area. Alapala Makina that is grown with its foreign business partners, has consider energy saving that is the most important subject of new term at its technologies. Alapala Makina Automation Manager Mehmet Baysal, who we interviewed about the subject emphasized that energy management is very important in flour factories as it is in every sector and establishment of energy tracking systems in processes is very important.
Mehmet Baysal pointed out that the mechanical problems that can be seen in the production machines directly affect the engine and increase the energy consumption and decrease the efficiency and life of the engines, gave information about energy management and energy recovery and the effects of the engines on the energy consumption and heat recovery methods for readers of Milling Magazine.
Mr. Baysal, what is the point of energy management and recovery in flour mills? Could you explain?
One of the most important criteria for enterprises to survive under severe competition conditions and increase their profitability is to reduce their fixed costs. Energy, one of the most important expenses, also occupies a specific expense rate depending on the type of business. Energy analyzes for the determination of energy efficiency in flour mills and other food sectors are of great importance.
How should the energy requirement-consumption be according to the processes in flour mills?
Energy is one of the most important criteria of today. At the new installations, efficiency is of great importance and power requirements are pulled down due to increased line capacities per ton. Energy consumption of 50-55 KW per ton is considered acceptable at an ideal installation.
Could you tell us about the methods of monitoring and measuring energy consumption in plants (periodic energy consumption analysis in operations)?
The establishment of energy tracking systems in processes is of great importance. With the energy tracking systems established in the plants, the energy consumed at different times of the day can be monitored.
What can you say about the effects of energy (power) supply systems on energy consumption and the correct positioning of these systems to save energy?
The energy supply systems in the processes have a direct impact on the energy consumption and the life of electrical equipment used in the process. Energy supply systems should not be below or above the motor label value. The voltage in the power supply system must be stable and at the desired value.
What are the effects on the energy consumption of electrification systems (hardware) and how should they be used correctly (cabling, lighting, heating, etc.) to save energy?
These systems have a direct impact on energy consumption. These systems need to be duly selected in accordance with the engine characteristics. Factors such as board material and engine cables that are not selected in accordance with the engine characteristics will cause the loss of energy as well as affecting the operation of the process negatively.
How do the engines affect energy consumption and how to choose the right engine (power, technology difference)?
The most important factor affecting energy consumption in flour mills is electric engines. Depending on where they are used, it is necessary to select the engines with suitable specifications. The power of the selected engines must be equivalent to the power it will expend. Enormous and powerful selection engines cause losses for the operation.
What should be the effects on the electricity consumption of the machines used in production (businesses) and what minimum characteristics should the production technology have for minimum energy consumption?
The machines used in production should be operated without any mechanical problems (friction, misalignment etc.) or by lowering the most. Mechanical problems will directly affect the engine, increase energy consumption and reduce the efficiency and life of the engines.
What are the contributions of automation and computerized control systems to energy saving?
There is considerable energy expenditure in the flour mills depending on the size of the process. Automation and control systems directly affect energy consumption in such processes. Many factors, from starting methods to operating frequencies of the machines used in automation systems affect energy consumption. Control systems must be in constant development.
What can you say about the contributions of periodic machines and mechanical maintenance to energy saving?
Planned maintenance on machines will reduce energy costs. For example; failures in the engine bearings will directly affect the friction on the engine, reducing the efficiency of the engine operation. Engine maintenance needs to be done periodically to avoid problems like this.
Could you give us information on heat recovery methods, systems & heat exchangers?
There is no need for external heat in grinding mills; steam heating and external heating systems are used only if there are pellet lines in the packaging units. The heat that is formed here is taken out of the product in the cooling bunkers and released outside. In addition, during the breakage of the wheat and pneumatic transport, there is also some heat release. This heat is also collected and released outside by the aspiration system.
There is a tendency for the new mills to use this heat in heating the building. The heat in the aspiration lines can be collected and transferred to the central heating system with heat exchangers.