This presentation provides detailed information about energy saving opportunties in food and beverage sector in Nepal. The status of various subsectors is shown and major energy saving opportunties are explained. The findings are based on a GIZ baseline study conducted in 200 industries in 2012.

1. Energy Efficiency Potential
Food & Beverage Sector
In Nepal

2. Food & Beverage Sector
Sub-sectors
 Beverage
 Biscuit
 Dairy
 Noodle
 Sugar
 Vegetable oil & Ghee

3. Beverage Sub-sector

4. Observations
 Beverage industries consume both electrical and
thermal energy
 Boilers are used for generation of steam and in most
of cases boiler fuel is diesel
 Use of re-winded motors
 Steam leakages are observed
 Insulation not satisfactory

5. Saving Potentials - Beverage
From ESPS studies, the potentials are 9.09% for
Electrical and 19.25% for thermal energy.
The electrical saving potential
= 0.0909 * 15300379 = 1,390,804 kWh
= 1,390.804 MWh
The thermal saving potential
= 0.1925 * 55,623,829 MJ = 10,707,587 MJ
= 10,707.587 GJ

6. Areas of Potential Savings
 Improvement in motor loading
 Replacement of old and rewinded motors by energy efficient
motors
 Minimization of energy losses by partition of cooling
areas, installation and effective use of air curtains
 Regular cleaning and maintenance of condenser pipes
 Improvement in the efficiency of capacitor banks
 Improvement in combustion efficiency in boilers
 Minimization of heat losses from the boiler
 Minimization of steam leakages
 Insulation of steam pipes, valves and flanges
 Improvement in steam supply system
 Condensate recovery
 Waste heat recovery

7. Biscuit Sub-sector

8. Observations
 Biscuit industries consume both electrical and
thermal energy
 Thermal energy required for baking process and
source of thermal energy is diesel
 Use of re-winded motors
 Insulation of oven not satisfactory
 Waste heat not recovered

9. Saving Potentials
Biscuit
ESPS studies - saving potential for electrical energy is
29.47% and thermal energy is 15.38%
The electrical saving potential
= 0.2947 * 3571208 = 1,052,435 kWh
= 1,052.435 MWh
The thermal saving potential
= 0.1538 * 56584558 MJ = 8,702,705 MJ
= 8,702.705 GJ

10. Areas of Potential Savings
 Improvement in motor loading
 Replacement of old and rewinded motors by energy
efficient motors
 Improvement in combustion efficiency in furnace
 Insulation of oven to minimize heat losses
 Waste heat recovery

11. Dairy Sub-sector

12. Observations
 Dairies use both electrical and thermal energy
 Boilers are installed to get steam for different
processes and in most of the cases boiler fuel is
diesel
 Use of re-winded motors
 Steam leakages
 Insulation of steam distribution system not
satisfactory
 Improper steam distribution lines
 Improper insulation of cold lines

13. Saving Potentials - Dairy
From ESPS studies, the potentials were 6.31% for
Electrical and 13.91% for thermal energy
The electrical saving potential
= 0.0631 * 7996867 kWh
= 504.602 MWh
The thermal saving potential
= 0.1391 * 91913748 MJ
= 12,785.202 GJ

14. Areas of Potential Savings
 Improvement in motor loading
 Replacement of old and re-winded motors by energy efficient motors
 Minimization of energy losses by partition of cooling areas, installation
and effective use of air curtains
 Improvement in insulation
 Introduction of modern/efficient belt and pulleys to the drives of
compressors
 Regular cleaning and maintenance of condenser pipes
 Improvement in the efficiency of capacitor banks
 Improvement in combustion efficiency in boilers
 Minimization of heat losses from the boiler
 Minimization of steam leakages
 Insulation of steam pipes, valves and flanges
 Insulation of walls and ceiling of incubation room
 Improvement in steam supply system
 Condensate recovery

15. Instant Noodle Sub-sector

16. Observations
 Instant Noodle industries consume both electrical
and thermal energy
 Boilers are installed to get steam for cooking
processes and boiler fuel is rice husk
 Use of re-winded motors
 Steam leakages
 Insulation of steam distribution system not
satisfactory
 Inefficient steam distribution lines observed

17. Saving Potentials - Noodle
ESPS studies have shown that the saving potential for
electrical energy is 6.15% and thermal energy is
11.38%.
The electrical saving potential
= 0.0615 * 3,956,752 kWh
= 243,340 kWh
= 243.34 MWh
The thermal saving potential
= 0.1138* 235,382,966 MJ
= 26,786,582 MJ
= 26,786.582 GJ

18. Areas of Potential Savings
 Improvement in motor loading
 Replacement of old and rewinded motors by energy
efficient motors
 Installation of capacitor banks
 Load management
 Improvement in combustion efficiency in boilers
 Minimization of steam leakages
 Insulation of steam pipes, valves and flanges
 Improvement in steam supply system
 Condensate recovery

19. Sugar Sub-sector

20. Observations
 Sugar mills need both electrical and thermal energy
 Installed with steam turbines to generate power for its
production process
 Sugar mills are installed with high pressure boilers and boiler
fuel is bagasse obtained from the crushing of canes
 Heavy motors are used for crushing, pumps, fans and
compressors
 Use of re-winded motors
 Capacitor banks are installed
 One of the sugar mills has surplus turbine capacity with
possibility to supply to central grid by cogeneration

21. Saving Potentials - Sugar
SEC is not useful due to lower consumption in the
country as the mills do not account for use of bagasse
The saving potentials from ESPS are 14.55% for
electrical energy and 20.73% of the thermal energy.
The electrical saving potential
= 0.1455 * 5,386,106 kWh = 783,678 kWh
= 783.678 MWh
The thermal saving potential
= 0.2073* 10,106,898 MJ = 2,095,160 MJ
= 2,095.16 GJ

22. Areas of Potential Savings
 Improvement in motor loading
 Replacement of old and re-winded motors by
energy efficient motors
 Improvement in the efficiency of capacitor banks
 Improvement in combustion efficiency in boilers
 Minimization of heat losses from the boiler
 Minimization of steam leakages
 Insulation of steam pipes, valves and flanges
 Improvement in steam supply system
 Condensate recovery
 Waste heat recovery

23. Vegetable Oil & Ghee Sub-sector

24. Observations
 Vegetable oil refinery industries consume both
electrical and thermal energy
 Boilers are installed to get steam for heating of oil at
different stages of processing and boiler fuel is rice
husk
 Use of re-winded motors
 Steam leakages
 Insulation of steam distribution system not
satisfactory
 Inefficient steam distribution lines observed

25. Saving Potentials Vegetable Oil & Ghee
n=16, Qs = 122,034 MT, Eo = 200 MJ/MT or 55.55
kWh/MT, To = 2700 MJ/MT
Σ(Ex-Eo) = 2100 MJ/MT, Σ(Tx-To) = 52442 MJ/MT
Electrical Saving Potentials
= (Qs/n) * Σ(Ex – Eo) = (122034/16)*2100
= 16,016,963 kWh = 16,017 MWh
Thermal Saving Potentials
= (Qs/n) * Σ(Tx – To) = (122034/16)*52442
= 399,981,689 MJ = 399,982 GJ

26. Saving Potentials
Vegetable Oil & Ghee
From ESPS studies, the potentials are 5.49% for
Electrical and 11.07% for thermal energy.
The electrical saving potential
= 0.0549 * 21,863,604 kWh = 1,200,312 kWh
= 1,200.312 MWh
The thermal saving potential
= 0.1107 * 705,371,030 = 78,084,573 MJ
= 78,084.573 GJ

27. Areas of Potential Savings
 Improvement in motor loading
 Replacement of old / re-winded motors by energy efficient motors
 Introduction of Variable Frequency Drives (VFD)
 Minimization of energy losses by proper insulation of cold
rooms, installation and effective use of air curtains
 Improvement in insulation of the cold pipelines
 Introduction of modern/efficient belt and pulleys to the drives
 Regular cleaning and maintenance of condenser pipes
 Improvement in the efficiency of capacitor banks
 Improvement in combustion efficiency in boilers
 Minimization of heat losses from the boiler
 Minimization of steam leakages
 Insulation of boiling pans, steam pipes, valves and flanges
 Improvement in steam supply system
 Condensate recovery
 Waste heat recovery from cooling of oil