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Annual Report 2017-18

The Bosch Energy and Building Solutions division is driving transformation in the realm of energy efficiency at manufacturing facilities around the country. This is achieved by designing innovative in-house solutions that are first tested at Bosch facilities and then augmented with digital analytics tools that transmit real-time data to make industrial facilities energy efficient.

At the Sri Mahalakshmi Dairy in Coimbatore, a reduction of 14% in the plant’s energy consumption was recorded after implementing Bosch’s energy efficiency solution. Furthermore, IoT sensors also enable the plant to achieve operational efficiency and monitor utility performance without interruption.

Two universal energy applications drive every global industry sector and manufacturing plant: heating and cooling. Maintaining energy efficiency during these core processes is, hence,of utmost importance to minimize carbon footprint. In India, the dairy industry is one such sector where these core energy functions constitute almost its entire energy mandate. The industry produces over 155 million metric tons of milk every year, the most in the world, and is one of the contributors to India’s position as the world’s third-largest emitter of CO2 due to its reliance on fossil fuels for heating purposes.

In light of this, dairy processing plants have long been on the lookout for sustainable alternatives that can reduce energy consumption and deliver long-term operational benefits. Bosch Energy and Building Solutions (BEBS), a business division of Bosch Limited, shares a similar vision and subsequently partnered with the Sri Mahalakshmi Dairy, Coimbatore, Tamil Nadu, to kickstart its journey towards sustainable energy efficiency while producing and distributing the ‘Aroma’ brand of milk products in India.

Transforming Lives

For decades, the dairy industry has relied on steam generation for its process heat requirements with little progress on either conserving energy or channelizing it efficiently. Karthikeyan N S, a Bosch Energy Efficiency solution expert, says, “Years of data has shown us that heat requirement in most dairies hardly ever cross 100 degrees. Steam generation results in the usage of large amounts of excess energy and delivers heat at a much higher temperature than these requirements. What this leads to is substantial wastage of both water and energy, and the need of the hour is a system that can deliver heat at the right temperatures based on real-time demands.” Enter Bosch with its Integrated Heating and Cooling Solution.

Bosch’s Energy Efficiency team customized a solution that optimizes heat generation utilities to provide real-time control over output. This innovative Bosch solution includes an IoT-sensor based monitoring system with a diverse set of indicators for effective process control.

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When quizzed on why they chose Bosch to implement this solution, Sri Mahalakshmi Dairy unilaterally agreed that Bosch’s previous experience in implementing effective energy efficiency solutions across industries such as manufacturing, automotive, steel re-rolling mills and commercial infrastructure was convincing.

As part of the team’s systematic approach to solving customer problems, Bosch’s energy experts first conducted a preliminary analysis of production zones where energy efficiency solutions could be integrated. As processes in the dairy industry utilize energy for heating and cooling while employing steam generators and chillers, the Bosch team devised a solution after studying the existing plant utility equipment. The team provided an estimate of how much energy efficiency, and thus cost saving, they could deliver.

The Transformative Bosch Energy Efficiency Solution

The core solution delivered by the Bosch Energy Efficiency team included the “Stratified Tank” – a cylindrical tank with a 15,000-liter capacity capable of storing and supplying heat to processes across the dairy plant at the exact temperature and time when needed.The solution is helping the plant balance its energysupply and demand requirements across processes and control energy flow. Another key aspect of the solution is the substitution of the steam utilized for low temperature processes with the water heated using heat pumps, heat recovery and economizers. Hence, the dairy plant was able to reduce the load on its steam boilers, thus providing greater flexibility in steam generation for other high temperature processes.

Additionally, the chilled water generated as a by-product is also supplied to coolers within the plant, thus ensuring that no energy goes waste. However, integrating such a solution into the dairy industry presents a significant challenge – always-on functionality. “Industries such as dairy processing function around the clock and cannot be interrupted even for system upgradation,” explains Nilesh Sawant, the Vertical Head for Energy Efficiency Solutions at BEBS. “The challenge, therefore, was to integrate our unique solution into the dairy plant without causing any disturbance to the processing function.”

Bosch addressed this challenge by retrofitting its energy efficiency solution with minimum disruption, mainly during the regular maintenance shutdowns. The result of the energy efficiency solution is an encouraging 14 percent reduction in the plant’s energy consumption. Production staff at the plant are also trained to optimally use the systems, thus making it self-sufficient and serving as an example for other dairy plants to draw inspiration from.

When it comes to energy efficiency, evolution never stops and neither does Bosch’s zeal for improvements. In the case of Sri Mahalakshmi Dairy, the team is integrating temperature and pressure sensors across the plant for real-time monitoring. With integrated energy meters and triggers in the mix, the future of energy efficiency promises to transform operations via unified energy dashboards that can be accessed from anywhere.

Bosch’s vision advocates reducing carbon footprints, and success at this dairy plant is a small step towards delivering successful energy efficiency solutions across the country. The company’s transformative energy solutions are a testament to its dedication towards promoting sustainability and future endeavors are primed to build a better world.

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We are committed towards a sustainable future for the entire ecosystem. Installed projects have helped customers reduce carbon footprints by over 130,000 metric tons of equivalent CO2 emissions annually. As we further customize solutions to suit needs, we are also integrating IoT solutions that help identify opportunities and better monitor performance with the help of data analytics.