Ehssan Wasef
Manager at Al Riyadh Mill & Silos
Wheat Milling Consultant
In the growing milling sector, energy efficiency plays a crucial role in reducing operational costs and enhancing sustainability. This article discusses the significant impact of advanced technologies, such as Variable Frequency Drives, smart control systems, and renewable energy sources, on the efficiency and environmental performance of milling operations. By adopting these solutions, mills can lower energy consumption, improve profitability, and contribute to global sustainability goals.
The milling sector is witnessing significant expansion with the entry of many companies into this field, leading to a diversity of offerings and improved services. However, one aspect that is often overlooked is the precise scientific analysis of energy consumption rates per ton of milled materials. Calculating electrical efficiency (kWh/ton) is a critical factor influencing operational costs and the competitiveness of companies.
In this regard, studies show that leading companies in the milling industry place great emphasis on improving energy efficiency by relying on advanced technologies and precise control systems to reduce electrical waste. On the other hand, some small or newly established mills face challenges in this area, especially when using equipment with low energy efficiency, leading to higher operational costs and reduced competitiveness.
Therefore, it is recommended to conduct comprehensive scientific studies to evaluate energy consumption in milling processes and adopt clear energy efficiency standards when designing or purchasing equipment. This approach will not only reduce operational costs but also enhance environmental sustainability and ensure the competitiveness of companies in a growing and demanding market.
CHALLENGES IN THE MILLING INDUSTRY
Energy Consumption and Its Impact on Costs and the Environment
Energy consumption is one of the main challenges facing the milling industry. Mills require large amounts of energy to operate equipment and meet production demands, leading to increased operational costs and negatively impacting profitability. According to studies, wheat mills consume between 65 to 100 kWh per ton of wheat, as reported by the Food and Agriculture Organization (FAO), with annual costs potentially exceeding $100,000. With rising energy prices, it becomes essential for mills to find ways to reduce consumption and lower associated costs.
Challenges Associated with Outdated Technology
Many mills rely on outdated equipment, resulting in low operational efficiency. This older technology is often inefficient in terms of energy consumption, increasing operational costs and reducing competitiveness. Additionally, these systems often lack modern features that allow for effective monitoring and control of energy consumption, making it difficult to improve overall plant performance. Estimates from the International Energy Agency (IEA) indicate that factories that do not adopt energy-saving solutions contribute to 40% of industrial emissions. Therefore, transitioning to modern technologies and renewable energy sources is not only an economic choice but also a commitment to environmental sustainability, helping to improve profitability and alleviate financial pressures caused by fuel and electricity costs.
Enhancing Energy Efficiency Using VFDs and Smart Control Systems
To enhance energy efficiency, mills can adopt Variable Frequency Drives (VFDs), which adjust motor speed according to production requirements, reducing energy consumption by 30-50%. VFDs work by changing the frequency of the electrical voltage applied to the motor to adjust rotation speed, thereby improving operational efficiency.
In addition, smart control systems, which use technologies such as the Internet of Things (IoT) and artificial intelligence, enable real-time performance monitoring and data analysis. These systems help identify patterns in energy consumption and provide recommendations for improving efficiency, reducing waste, and enhancing competitiveness.
When using VFDs in wheat mills, motor speeds can be adjusted based on actual production needs rather than maintaining constant speeds. For example, if a mill needs to process a smaller quantity of wheat during a specific period, motor speeds can be reduced, lowering energy consumption. This adaptation allows for significant energy savings of up to 30-50% in some cases, while also reducing mechanical stress on equipment and extending its lifespan.
In mills, smart control systems are used to monitor equipment performance and energy consumption. For instance, a smart control system can collect data on motor energy consumption at high speeds compared to reduced speeds. If it detects that certain components are consuming more energy than necessary, the system can alert operators to adjust settings or perform maintenance. Additionally, these systems help improve processes by reducing material waste, enhancing operational efficiency.
Summary of Benefits:
- Reduced operational costs
- Improved production efficiency
- Accurate data for decision-making
- Lower maintenance costs and extended
equipment lifespan
The Role of Innovation in Enhancing Sustainability in the Milling Industry
Technological innovations in the milling industry are vital for enhancing sustainability and efficiency. With increasing environmental and economic pressures, companies are striving to achieve better performance using modern technologies that support sustainability.
1. Improving Processes Through Innovation
Technological solutions such as big data analytics allow for the collection and interpretation of data from various production stages to identify opportunities for performance improvement. These analytics enable mills to monitor consumption practices and discover areas where waste can be reduced and energy efficiency improved.
2. Improving Lighting Systems
When starting a project, natural lighting should be considered to reduce electricity expenses. Lighting can consume a significant portion of the energy used in mills. Switching to LED lighting can reduce energy consumption by up to 7.5%. Studies indicate that this transition not only saves on energy costs but also contributes to reducing carbon emissions (EPA, 2022).
3. Using Renewable Energy Sources
Many mills are integrating renewable energy sources such as solar and wind power into their operations. These energy forms can reduce reliance on fossil fuels for electricity generation.
Future Trends in the Milling Industry
1. Internet of Things (IoT)
The application of IoT in the milling industry can enhance the sustainability of operations. By using connected devices, machine performance can be continuously monitored, helping to detect issues in real time and allowing for preventive maintenance before failures occur.
2. Automation and Adaptive Technology
Automation enables continuous control of production lines, improving productivity and energy efficiency. Smart, adaptive systems can adjust milling processes based on actual usage, reducing waste and increasing the effectiveness of material consumption.
BENEFITS OF ENERGY-SAVING SOLUTIONS
1. Financial Impact
Energy-saving solutions contribute to significant cost savings, with estimates suggesting that mills adopting these strategies can save between $30,000 to $50,000 annually. These savings enhance investment returns and increase market competitiveness.
2. Environmental Impact
Reducing energy consumption helps lower carbon dioxide emissions by up to 20%. These efforts align with the goals of governments and environmental organizations to promote sustainability and achieve global climate targets.
INTEGRATING ARTIFICIAL INTELLIGENCE IN WHEAT MILLS
1. Improving Milling Processes Using AI
Artificial intelligence technologies can significantly improve milling processes by collecting operational data and assisting in real-time decision-making. This enhances overall efficiency and reduces waste. AI also helps improve energy management by predicting peak times, with studies from the Energy Research Center showing that optimizing operating times can save up to 20% of energy.
2. Predictive Maintenance
Predictive maintenance is one of the major benefits of AI, allowing for the analysis of operational data and the prediction of failures before they occur. This helps reduce costs associated with unexpected repairs and ensures continuous production.
3. Using Big Data
Future wheat mills will rely on big data to improve all aspects of operations, from supply chain to production. This data is used to analyze trends and improve strategic planning using AI for data analysis, enabling the identification of weaknesses and available solutions.
Improving energy efficiency in flour mills is a wise investment to enhance competitiveness and achieve environmental sustainability. By adopting technologies such as VFDs, smart control systems, and renewable energy, mills can significantly reduce operating costs while minimizing their carbon footprint. In the future, advanced technologies like artificial intelligence and the Internet of Things will play a pivotal role in transforming the milling industry into a more efficient and sustainable sector.
About the author:
Ehssan Wasef is a seasoned professional in the food production industry with over 20 years of experience in wheat milling. His career began in 2003 at a state-of-the-art mill, where he advanced through various roles up to production manager, supported by a master’s degree in agricultural engineering. Currently, he consults for investors in the wheat milling sector, leveraging his expertise in machine configuration and selection to ensure high-quality production. He has sourced top-tier equipment from leading Turkish manufacturers and, through thorough project analysis and meticulous oversight, ensures optimal performance, contributing significantly to project success and efficiency.
References:
1. International Energy Agency (IEA). (2019). Energy Efficiency in Industry.
2. U.S. Department of Energy. (2020). Variable Frequency Drives and Energy Savings.
3. National Renewable Energy Laboratory (NREL). (2021). Energy Efficiency for Textiles and Fiber Mills.
4. U.S. Environmental Protection Agency (EPA). (2022). Indoor Air Quality and Energy Efficiency.
5. International Renewable Energy Agency (IRENA). (2021). Renewable Energy Benefits.