Manufacturing Industry

Industrial cogeneration: optimal energy management and less consumption

The use of cogeneration and trigeneration plants offers a whole host of potential benefits in a number of different sectors and industrial applications.

The manufacturing industry’s energy consumption is often considerable, with costs that make up a significant portion of overall indirect costs.
The most sustainable way to tackle the problem of increasing energy costs is to use energy better and use less of it.
Industrial cogeneration plants can guarantee significant savings in the costs of fuel required for electricity and heat production, with an application range that meets the demand for energy from the manufacturing industry.

Cogeneration plants are ideal in different industrial sectors. For example, in the beverages industry, AB plants can be used in the manufacture of preforms and the development of energy efficiency in processing, as they decrease the impact of specific costs and help boost business profitability.
AB cogeneration plants are greatly appreciated by the pharmaceutical industry, as they offer technological solutions which are ideal for organisations with a massive, continuous need for electricity, hot water and steam. These same benefits are also available to the paper and food industries, to improve their manufacturing competitiveness, combining economic advantages with a tangible focus on environmental protection.

FOOD INDUSTRY

RAW & CURED MEATS

RAW MEATS

Slaughterhouses and/or meat by-product processing companies.

HEAT REQUIREMENTS

They require:

  • steam for production processes;
  • hot water for washing, regulating moisture in processing areas, and heating in winter months.

REFERENCES

ADGS – Amadori – Ilta – Inalca – Prosus

 

CURED MEATS

Companies that produce cured-raw (salami, prosciutto, and speck), and cured-cooked (prosciutto, würstel and mortadella) meats.

HEAT REQUIREMENTS

They require:

  • steam for cooking the meat;
  • hot water pfor aging and/or processing raw meats.

REFERENCES

Espuna – Salumi d’Emilia – Senfter – Spiezia.

 

DAIRY PRODUCTS

MILK PROCESSING PLANTS

Milk processing involves very specific production cycles. These cycles require a significant amount of energy, especially those relating to heating products and the plant.

HEAT REQUIREMENTS

They require:

  • steam, primarily;
  • hot water for some production processes, such as pasteurization, washing and packaging.

REFERENCES

Capsa – Granarolo – Imlek – Mila – Mukki – Latte Milano – Sterilgarda.

 

CHEESE FACTORIES

Cogeneration is strategically important for cheese factories since they require massive amounts of electrical and thermal energy for production processes.

HEAT REQUIREMENTS/strong>

They require:

  • steam, primarily;
  • hot water for some production processes, such as aging and washing.

REFERENCES

Belladelli – Galbani – Kraft – Lactalis – Latteria Montello – Latteria Soresina.

 

CONFECTIONARY PRODUCTS

Production processes suitable to trigeneration.

HEAT REQUIREMENTS

They require:

  • steam, primarily;
  • hot water for washing and heating in winter months;
  • cold water (7°C/12°C) for conditioning and production processes.

REFERENCES

Eridania – Ferrero – Icam – Lindt – Menz&Gasser – Nestlè.

 

PASTA FACTORIES

Production processes suitable for trigeneration which require a substantial amount of energy to be used.

HEAT REQUIREMENTS

They require:

  • super-heated water for production processes and pasta drying;
  • cold water (7°C/12°C) for pasta cooling prior to packaging.

REFERENCES

Buitoni – Esselunga – Italfood – Pastificio Garofalo – Pastificio Guido Ferrara – Pastificio La Molisana – Pastificio Rummo.

BEVERAGE INDUSTRY

Beer, liquors, fizzy drinks, fruit juices, and mineral water require substantial consumption of electrical energy.

HEAT REQUIREMENTS

They require:

  • steam;
  • hot water for production processes, washing glass bottles and pasteurization.

REFERENCES

Birra Estrella Damm – Caviro – Cinzano – Coca-Cola – Distillerie Bonolli Umberto – Distillerie Mazzari – Martini & Rossi – Peroni – Spumador.

CANNED FOOD INDUSTRY

Production of preserved fruits, vegetables and tomatoes and jams.

HEAT REQUIREMENTS

They require:

  • steam, primarily;
  • hot water to heat boiler make-up water and for pasteurization, washing and heating.

REFERENCES

Coelsanus – Industrie Rolli Alimentari – Orogel – Valfrutta.

tessileTEXTILE INDUSTRY

Cogeneration is ideal for the textile industry, which is highly energy-intensive in terms of both electrical and thermal energy.

HEAT REQUIREMENTS

They require:

  • steam, primarily;
  • hot water for production processes.

REFERENCES

Benetton – Borsalino – Cotonificio Albini – Felli Color – Marzotto Italdenim – Santex.

farmaceuticoPHARMACEUTICAL INDUSTRY

Cogeneration is strategic for the pharmaceutical industry, which is highly energy-intensive in terms of both heat and power and requires a continuous flow of energy for the conditioning of clean rooms, laboratories, and storage warehouses.

HEAT REQUIREMENTS

They require:

  • steam;
  • hot water for conditioning (even in warm months);
  • cold water, at times.

REFERENCES

Farmacéutica Cataluña – Fatro – Lilly – Kedrion – Olon – Patheon – Pfizer – Sandoz – Valpharma.

chimico_petrolchimico_estrattivoCHEMICAL, PETROCHEMICAL, MINING INDUSTRIES

Cogeneration is ideal for chemical, petrochemical and mining industries since they are higly energy-intensive in terms of both electrical and thermal energy.

HEAT REQUIREMENTS

They require:

  • steam, primarily;
  • hot water;
  • cold water.

REFERENCES

Basf – Coim – Compton Petroleum – Mapei – Momentive – Viscolube.

plasticoPLASTIC PRODUCTION INDUSTRY

Production processes suitable for trigeneration. They are highly energy-intensive.

HEAT REQUIREMENTS

They require:

  • cold water;
  • diathermic oil.

REFERENCES

Cartoplastica – Cellografica Gerosa SpA – Di Mauro Officine grafiche SpA – Eurosak – FLO SpA – Pirelli cavi e sistemi – Serioplast SpA – TPV Compound.

BRICK INDUSTRY

Cogeneration is strategic for the brick industry, which relies upon continuous production cycles that require constant absorption of both electrical and thermal energy.

HEAT REQUIREMENTS

They require:

  • hot water to heat air during brick drying after the formation phase.

REFERENCES

Capabil – Carrice La Farge – Fornace Danesi – Laterizi Donati – Sibelco – Wienerberger.

CERAMIC INDUSTRY

The ceramic industry is highly energy-intensive both in terms of electrical and thermal energy.

HEAT REQUIREMENTS

They require:

  • hot water to heat air.

REFERENCES

Ideal Standard.

cartierePAPER MILLS

Cogeneration is ideal for paper mills since they require large amounts of both electrical and thermal energy.

HEAT REQUIREMENTS

They require:

  • steam, primarily;
  • hot water in production processes (pre-heating of boiler make-up water; pre-heating of water for chemical dosing; process water heating; pulper heating; heating de-humidifying air in the continuous-cycle machine room; heating hood air coming from the recuperator and before it enters the battery stream boiler; heating high-pressure spray water).

REFERENCES

Bartoli – Cartiera Saci – Cartiera Cooperativa di Rivalta – Cartiera di Mondovì – Cartiera del Polesine – Cartiera di Bosco Marengo – Cartiera di Momo – Cartiera di Cologno Monzese.

MECHANICAL AND METALLURGICAL INDUSTRY

GALVANIZING INDUSTRY

Galvanizing companies and companies whose production cycles include galvanization processes require significant amounts of energy.

HEAT REQUIREMENTS
They require:
steam;
hot water to maintain galvanic baths at the required temperature;
heated water;
cold water;
diathermic oil.

REFERENCES
Galvanotecnica – SBE – Silga

 

COATING INDUSTRY

Factories whose production cycles also require coating processes require significant amounts of energy.

HEAT REQUIREMENTS
They require:
steam;
hot water to dry paint;
heated water to dry product after rust-proofing;
cold water;
diathermic oil.

REFERENCES
Becromal – Brass Thecnical Systems – Cromodora – Denso – I.T.T. – Trasma

pellamiLEATHER INDUSTRY

Leather processing factories require substantial amounts of energy.

HEAT REQUIREMENTS

They require:

  • steam;
  • hot water;
  • heated water.

REFERENCES

Associazione conciatori S. Croce – Assocogen Zermeghedo – Associazione conciatori San Miniato – Russo di Casandrino.

legnoWOOD INDUSTRY

Wood processing companies require substantial amounts of electrical energy.

HEAT REQUIREMENTS

They require:

  • steam in production processes;
  • hot water during drying.

REFERENCES

Luigi Brocca & Figli SpA; Reni Ettore; Invernizzi.