Mill Energy Efficiency: Innovative Solutions for Sustainable Production”
Typical energy distribution in mill facilities:
- Grinding Operations (Roll System): 40-45% of total consumption
- Pneumatic Conveying Systems: 15-20%
- Elevators and Conveyors: 10-12%
- Cleaning and Tempering Equipment: 8-10%
- Ventilation and Aspiration: 7-9%
- Lighting and Other Systems: 8-10%
Main causes of energy loss in non-optimized facilities:
- Inefficient motor systems and constant speed equipment
- Inadequate insulation and heat losses
- Non-optimized process flow
- Leaks and pressure losses in pneumatic systems
- Old lighting systems
- Manual control systems
Average Energy Consumption Values in the Industry
In the milling industry, an average of 70-120 kWh of electricity is consumed to process one ton of wheat:
| Facility Category | Energy Consumption (kWh/ton) | CO2 Emission (kg/ton) |
|---|---|---|
| Old Technology | 100-120 | 50-60 |
| Efficient Technology | 60-80 | 30-40 |
| High Efficiency | 40-60 | 20-30 |
Impact of Energy Efficiency on Competitiveness
Competitive advantages that energy efficiency provides to businesses:
- Low production costs and competitive pricing
- Increased brand value with sustainability image
- Resistance to energy price fluctuations
- Compliance with legal regulations and benefiting from incentives
Smart Motor Systems and Variable Frequency Drives
- Premium Efficiency Class Motors: Motors that consume 10-15% less energy
- Smart Frequency Converters: Automatic motor speed adjustment according to capacity changes
- Soft Start Systems: Units that extend motor life and reduce starting energy draw
- Motor Monitoring Systems: Sensors and software that ensure operation at optimum efficiency point
These technologies provide 15-30% energy savings for a single motor.
High-Efficiency Grinding Equipment
- Aerodynamic Roll Design: Roll structure that reduces friction and heating
- High-Performance Roll Balls: Special surface coatings that increase energy efficiency
- Efficient Sifter Systems: Low energy consumption screening systems
- Smart Grinding Control: Automatic parameter adjustment according to wheat characteristics
Our innovative grinding technologies provide 20-25% energy savings compared to traditional systems.
Heat Recovery Systems
- Motor Heat Recovery: Use of heat released from large motors in the facility
- Roll Cooling Water Heat Exchangers: Recovery of heat in cooling water
- Compressor Waste Heat Recovery: Utilization of heat released from compressors
Our heat recovery systems reduce heating costs by 30-50%.
LED Lighting and Sensor Technologies
- Industrial LED Lighting: Lighting that provides up to 70% energy savings
- Motion and Daylight Sensors: Sensors that provide automatic lighting control
- Zone-Based Lighting Control: Customized lighting scenarios for different areas
Automatic Capacity Adjustment Systems
- Smart Capacity Control Software: Automatic adjustment of equipment capacity according to production plan
- Load Sensors: Determining optimum feeding speed by measuring system load
- Dynamic Pressure Control: Automatic adjustment of pressure level in pneumatic systems
- Variable Flow Fan Systems: Adjusting fan speed according to air flow requirement
These technologies provide 15-25% savings in total energy consumption.
High-Insulation Equipment
- Thermally Insulated Cabinets: Insulation materials that minimize heat loss
- Efficient Pneumatic Conveying: Special coatings and seals that prevent air leakage
- Insulated Storage: Systems that minimize humidity and temperature changes
Insulation improvements typically provide 5-10% energy savings.
Energy Monitoring and Management Software
- Real-Time Monitoring: Instant tracking of energy usage in different parts of the facility
- Anomaly Detection: Smart systems that detect abnormal energy consumption
- Reporting and Trend Analysis: Analysis of energy efficiency performance
- Remote Monitoring: Remote tracking of facility energy performance
Energy monitoring systems typically offer 5-15% additional savings potential.
Average 20-40% Savings in Energy Costs
- 20-40% reduction in electricity consumption
- 30-50% decrease in heating costs
- Reduction in maintenance costs
- Increased operational efficiency
Customers typically recover the investment cost of efficiency projects within 2-3 years.
Carbon Footprint Reduction
- 20-40% reduction in CO2 emissions
- Green certification advantage
- Environmental impact reporting
- Preparation for carbon tax and regulations
Improvement in Production Capacity and Equipment Life
- More stable process control
- Reduction in downtime
- Less wear and heating in equipment
- Proactive maintenance opportunity
Decrease in Operating Expenses and Sustainability Advantages
- Reduction in direct energy costs
- Decrease in maintenance and labor expenses
- ISO 50001 and other certification advantages
- Opportunities to benefit from government incentives
Environmental Benefits and Certification
- CO2 Emission Reduction: Annual reduction potential of 500-2000 tons CO2 equivalent
- Sustainable Production Certificates: Compliance with standards such as ISO 50001, 14001
- Green Factory Transformation: Holistic approach covering energy, water, and waste management
Current Facility Analysis and Reporting
- Detailed Energy Audit: Analysis of facility energy consumption patterns
- Equipment-Based Measurements: Measurement of energy consumption of main equipment
- Thermal Camera Analysis: Visualization of heat losses
- Savings Potential Report: Prioritization of identified improvement areas
Customized Solutions and Implementation Support
- Solutions According to Facility Characteristics: Technologies suitable for your existing equipment structure
- Phased Implementation Plans: Gradual implementation according to budget and operational constraints
- Investment Analysis: Detailed feasibility and payback period calculations
- Implementation and Commissioning Support: Successful implementation of projects
- Performance Verification: Measurement of actual performance of implemented projects
Mill Energy Efficiency: Innovative Tech for Sustainable Production
In today’s milling industry, energy consumption accounts for 30-40% of operating costs. As Tanış A.Ş., we optimize the energy consumption of your mills with the innovative technologies we develop, both reducing your costs and contributing to sustainability.
Our efficiency solutions provide 20-40% energy savings in mill facilities, enabling your investment to pay for itself within 1-3 years. Our energy optimization approach reduces energy costs while extending equipment life and reducing your carbon footprint.
Energy Efficiency Investment and Financing
Investment Analysis and Financing Options
- Detailed Feasibility Studies: Financial return calculations of investment
- Incentive and Support Programs: Opportunities to benefit from government support
- Energy Efficiency Financing: Low-interest loans and grants
- ESCO Model: Performance-guaranteed energy efficiency projects
Frequently Asked Questions
The payback period for projects typically ranges from 1-3 years. Low-cost projects such as lighting can pay for themselves in less than 1 year, while comprehensive system modernizations can amortize within 2-3 years.
Energy efficiency projects do not reduce production capacity; on the contrary, they can increase efficiency by providing more stable operating conditions. Energy optimization and more stable system operation positively affect production quality and consistency.
Most energy efficiency applications can be carried out during planned maintenance shutdowns. Production interruption can be minimized with phased implementation plans. For critical equipment, work can be done on weekends or during low production periods.
Integration of energy-efficient technologies is easier and more cost-effective in new facilities. However, we also have retrofit solutions for existing facilities. Existing facilities usually have higher savings potential and improvements can be implemented gradually.
Energy-efficient systems generally require less maintenance. Modern monitoring systems offer proactive maintenance opportunities, reducing failure times. However, some advanced technology systems may require specialized maintenance personnel training.