Efficiency consulting in the processing industry: How to increase your competitiveness
As energy costs continue to rise and pressure mounts on companies to address climate change, the issue of efficiency is rapidly gaining momentum in the processing industry. In particular, thermal processes often consume more energy than necessary, whether for drying, concentration, pasteurization, or sterilization. This is where efficiency consulting comes in: By analyzing and optimizing existing plants, you cannot only reduce operating costs. You can also significantly reduce your CO₂ footprint. This blog post explains why professional efficiency consulting pays off, how it works, and how it can save you millions every year.
What is efficiency consulting?
“Efficiency consulting” refers to the structured and expert analysis of production processes, followed by individually tailored measures to improve energy and resource efficiency. This is especially useful in the processing industry, as thermal processes are particularly energy-intensive. Unnecessary energy consumption can result from outdated technology, inadequate heat recovery, or suboptimal processes.
A professional efficiency consultant not only identifies where energy and costs can be saved, but also develops technical solutions that improve quality and productivity. In the long run, this contributes significantly to the company's success and competitiveness. And it's good for the environment.
The three-step approach of DEVEX to energy efficiency and process optimization
DEVEX draws on a wealth of experience in thermal processes to help you improve efficiency using a proven three-step approach. This ensures that implementation is not only fast, but also technically sound and sustainable.
Step 1: Analysis of energy consumption and production processes
In the first step, DEVEX takes an overview of your production plants and identifies possible weak points. The following areas are examined for potential improvements:
- Energy consumption: Where is energy being wasted? Is heat recovery an option?
- Product quality: What factors are affecting quality and how can it be improved?
- Productivity: Where are the bottlenecks or inefficient processes that add unnecessarily time and cost?
This analysis forms the basis for an initial assessment of the potential for cost reduction and the level of investment required. From this, a robust business case can be built that shows how quickly improvements can pay for themselves.
Step 2: Pre-engineering study for sustainable process optimization
In the pre-engineering phase, DEVEX develops a technical concept that includes flow diagrams, mass and energy balances, and an exact cost calculation. With this information, you can make a binding decision as to which measures offer the best cost-benefit ratio and whether you want to implement them.
Step 3: Implementation – from planning to successful commissioning
Whether you are modernizing an existing plant or installing new technology, DEVEX can support you throughout the entire implementation process. Ongoing post-implementation monitoring and fine-tuning ensures that the measures taken result in sustainable efficiency gains.
Reducing CO₂ footprint and operating costs
Professional efficiency consulting offers a number of tangible benefits:
- Reduced operating costs: By optimizing your use of energy and materials, you can significantly reduce your operating costs.
- Reduced CO₂ footprint: Through more efficient processes, you can reduce your energy consumption and make an active contribution to environmental protection.
- Improved process and product quality: Consistent production processes improve the quality of the final product, which has a direct impact on customer satisfaction and brand image.
- Unbiased analysis: The outside perspective of independent consulting reveals blind spots and entrenched thinking patterns.
- Clear decision-making: A structured approach with reliable figures provides transparency and enables an informed investment decision.
- Rapid payback: Many improvements pay for themselves in a short period of time – and then make a lasting contribution to increased profitability.
An instant coffee manufacturer saves millions of dollars by optimizing its thermal processes.
A specific project at an instant coffee manufacturer in South America illustrates the potential of professional efficiency consulting. The existing extraction plant was over 40 years old and inefficient.
A systematic three-step analysis was conducted to determine which processes were outdated and which measures had the greatest potential for success. The result: the installation of a more modern extraction and evaporation plant that requires significantly less energy while increasing production capacity.
For the customer, the reduced energy and raw material consumption alone meant annual savings of several million dollars. Best of all, the investment is expected to pay for itself in less than 2.5 years. In addition, more consistent production conditions and optimized process parameters resulted in a visible improvement in product quality.
Conclusion and outlook
If you want to remain competitive while actively protecting the climate and the environment, there is no way around professional efficiency consulting. The processing industry, in particular, often has tremendous savings potential - both in terms of energy and associated costs.
Are you interested in improving your efficiency?
Then let DEVEX provide you with a no-obligation consultation and find out how you can take your production processes to the next level - for greater sustainability, lower costs and long-term competitiveness.