Energy management in food manufacturing

SOLVERA LYNX CASE STUDY

ENERGY MANAGEMENT IN FOOD MANUFACTURING

A food industry company operating across multiple locations, with production covering bakery and milling products, frozen foods, confectionery, chewing gum, chocolate, biscuits, pasta, spices, teas, rice, and retail operations, was facing challenges typical of energy-intensive processes.

Extensive refrigeration systems, ovens, HVAC equipment, and highly dynamic production schedules resulted in high energy consumption, frequent anomalies, and limited visibility into site- and process-level usage. This hindered optimization efforts, increased costs, and reduced the ability to respond promptly to deviations.

KEY CHALLENGES BEFORE SYSTEM IMPLEMENTATION

Resource Consumption

Electricity

Number of Facilities

12

Data Sources

40

Main Electricity Consumers: Refrigeration and freezing technologies, HVAC systems, lighting

PROJECT OBJECTIVES

  • Ensure accurate, real-time visibility into energy consumption
  • Reduce energy costs without impacting production
  • Identify process inefficiencies, particularly in ovens and refrigeration systems
  • Establish a systematic approach to energy management and temperature control
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SOLVERA LYNX SOLUTIONS

Solvera Lynx implemented a comprehensive energy management system that includes:

1. Automated Data Collection

Data acquisition at key production points (at 15-minute intervals) and transmission to the GemaLogic platform

2. Advanced Analytics and Transparency

Real-time consumption monitoring by facilities, processes, and end users

2. Alarm System

Detection of deviations in temperature, consumption, or costs (e.g., sudden consumption spikes, water leaks)

4. Oven Utilization Analysis

Based on usage intensity and operating patterns

5. Cooling System Monitoring

Cold chain supervision, where the most significant anomalies were identified

6. Benchmarking and Performance Comparison

Decision support for optimization initiatives

RESULTS

Comprehensive visibility into energy consumption across 12 locations
Immediate detection and elimination of inefficiencies
Optimization of key consumers: ovens, HVAC, and refrigeration systems
Reduced energy costs without disrupting production processes
Improved company-wide energy efficiency

WHAT DID THE COMPANY GAIN?

Accurate Energy Profile

A reliable foundation for informed decision-making

Improved Temperature Management

Better control of critical production and storage conditions

Faster Response

Rapid corrective actions in case of deviations

Continuous Improvement

In line with the principles of continuous energy management

Financial Savings

Reduction of energy costs by 15–20%

Decision Support

Data-driven input for strategic investment planning

Equipment Maintenance

Regular maintenance of hardware and software systems

Asset Management

More efficient utilization of existing equipment

ISO 50001 Compliance

Support for structured energy management systems

ESG Reporting

Transparency in sustainability performance
Through a comprehensive approach to energy management, the company achieved not only lower costs but also systematic control that enables long-term efficiency and competitiveness in the demanding food industry.

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