• Always treat water as a raw material with a real cost. Water charges will continue to increase.
• Water consumption varies from 1 to 5 litres for processing 1 litre of milk. High water consumption will make availability critical.
• Water saved does’t hare to be in-house treated or heated.
• Install water meters and monitor water use.
• Use high pressure, low volume cleaning system.
• Use automatic shut off nozzles on all water hoses.
• Survey water use and waste production in the plant.
• Improve maintenance to prevent product leaks from valves, piping and equipments.
• Carry out waste water analysis. It is useful to indicate a plant’s processing efficiency including the product going down the drain.
• Design and install lines that will allow proper draining of product rather than relying on rinse water to remove product.
• Plan batch scheduling. Reducing the number of change overs will minimize losses of products.
• Reuse process water from high volume pasteurizing unit.
• Use reclaimed water
  • To supply boilers
  • For heating/cooling heat exchangers
  • For flushing products from process equipments.
  • For hose stations
  • For cleaning and sanitizing milk trucks.
• Install screens on all drains.
• Segregate strong acid or alkali waste streams and use them for pH control in waste water treatment.
• Recover Heat from Milk Cooling systems while cooling from 39⁰C to 3⁰C for safe storage. The average preheated water temperature from water cooled condensing mechanism is likely to be in the range 50⁰ to 60⁰C.

• For efficient combustion pre-heat the oil to have temp between 1050-1100C at burner tip and optimize air to fuel ratio.
• To stop abrasive particles FO filtration system should have filter mesh sizes as follows.
  

a. Between Lorry & main storage tank-mesh size 10
b. Between service tank & pre-heater- mesh size 40
c. Between pre-heater and burner- mesh size 100

• Provide water draining facility and regularly drain water. This reduces sludge formation and other problems like erosion of burners and damage to the refractories.
• It is preferred to have parallel FO pumps of smaller capacity than one pump of larger capacity to avoid unnecessary re-circulation of huge quantity of FO.
• Replace electric preheaters with steam coil preheater for DG set fuel since steam is cheaper source than electricity and is available at site.

• Control excess air with oxygen at 3.0 to 4% level in flue gas.
• Air flow to fuel feed rate should be controlled for oxygen level around 3.0 % in flue gases.
• Normally flue gas temperature is beyond 4000C. To recover waste heat install/replace air-preheater of required capacity and pre-heat the air.
• Maintain TDS in boiler. If required install an automatic blowdown system.
• Maintain stack temperature in the range of 1800-2000 C by oil pressure adjustment, burner cleaning, filtering fuel, soot & scale removal and excess air to 3 %. Any rise in flue gas temperature of more than 200C normal temperature soot blowing can be carried out.
• Remove scale in ghee boilers to improve heat transfer which results in reducing steam consumption.

• Condensate recovery from pastureizers, ghee boilers, milk packing can be used for hot water requirement for cleaning.

• Improve insulation and cladding of DG sets exhaust
• Insulate Flanges & valves to minimize heat loss. Insulation is to be of boxed type for maintenance ease.
• Steam line, boiler feed water lines to be checked periodically and damaged insulation to be repaired immediately.
• Improve insulation if the surface temperature exceeds 600C. Ensure that proper insulating material and thickness is provided for proper insulation.
• Regularly check the cold insulation and repair them immediately to reduce heat loss.
• Arrange or ask for Industrial training programme in your cluster once a year.

• Replace cooling tower conventional aluminum alloy blade with FRP blades of same profile.
• Install automatic temperature controller for cooling water pumps.

• Reduce compressed air pressure from 8 Kg/Cm2 to 7.0 Kg/Cm2 where ever possible to conserve energy, when required pressure at usage point is 6.0 Kg/Cm2
• Stop use of compressed air for floor cleaning.
• Check for compressed air leakage and arrest it.
• Switch off one compressor if requirement can be met by balance operating compressors.

• Maintain suction and discharge pressure as per design parameters. Higher discharge pressure may call for condenser dechoking, gas filling, cleaning of coils etc.
• Water cooled condensers will reduce compressor running time.

Motors:

• Replace underloaded / overloaded motors with proper size motors. Replace the motors with energy efficiency motors.

• Replace 40W Tube light by slim 28W Tube light and electromagnetic choke with electronic choke.
• Replace 400 Watt Mercury Vapour lamps with 250 Watt sodium vapour lamps or 250 W metal hallide lamps.
• Replace 250 Watt Mercury Vapour lamps with 150 Watt sodium vapour lamps or 150 W metal hallide lamps.
• Provide more transparent sheet instead of asbestos sheets to use natural light.
• Install energy saver for reducing the lighting load.
• Rationalize lighting in identified areas i.e remove excess lighting in identified areas. Also relocate lighting, if necessary.

Contract Demand :

• Provide demand controller with an alarm provision in case it exceeds contracted demand.
• Review and reduce the contract demand.

• If possible switch off one transformer running under loaded in parallel. Maintain all transformers at a loading of 70 to 80 % of rated capacity to minimize loss component (no load losses).
• Try to have separate transformer for lighting where voltage can be kept low.

• Improve power factor by regular checking of current of all the capacitors and their timely replacement.
• Install Automatic power factor correction device to have power factor of 0.99 to 1.00