Analysis of Energy Use in the Ceramic Membrane Filter Plant and in the United Distillers Vintners Plant [a Case Study at Kenya Breweries Ltd]

Abstract

The global challenge on energy has been there for some period, this is being driven by the need for safer clean and environmentally friendly sources of energy. Currently most of the world production utilizes electricity and heavy fuel oil. High costs of production has driven the mitigation against the high cost energy in beer production. The best way to lower the energy cost of production is by analyzing of the existing system with a view of making cost effective improvements. The brewing process is energy intensive operation right from the onset at the brew house to the packaging lines. This project focused on energy analysis of UDV plant and the CMF plant. Data was collected on both plant during the study period and analyzed to evaluate areas of energy savings opportunities. In this regard the UDV plant sugar boiling system was analyzed and modifications proposed. The modifications will be able to safe 33.3% of the steam used translating to ksh3.56 million per year. The UDV packaging lines was also modified to incorporate proximity sensors which can save 3% of the energy used translating to 83,643 ksh per year. The power factor correction bank analysis identified a gap which when the solution is implemented can give 43.4% return on investment. CMF operation was modified at the yeast transfer section resulting to saving of between 3.8% to 9.4%. The yeast harmonization section was optimized reducing the time from one hour to 20 minutes, further research work was proposed for both plants to lower the cost of production.