The Italian food sector represents excellence that excels in quality, food safety, cutting-edge technological innovation, sustainability, biodiversity and respect for tradition.
Italy is a country characterised by great territorial and climatic diversities that have moulded themselves into exceptionally varied and unique cultures, histories and traditions. These characteristics have led to the formation of a large number of small and large companies that, faced with the impossibility of competing on foreign markets in terms of price reductions, have focused on enhancing the uniqueness of their products.
Improving the efficiency of machines in food industry
The bread industry deserves a separate mention: industrial bread is not necessarily synonymous with low-quality or second-rate bread. Producing high-quality industrial bread for large-scale distribution is possible thanks to the ability of production lines to process a high number of doughs per hour. In order to be defined as ‘fresh’, the bread must be prepared according to a continuous production process, with no pauses between the kneading and baking phases, with no interruptions aimed at freezing or deep-freezing, except for slowing down the leavening process.
CD Automation ensures a marked improvement in the performance of machines for the food industry by focusing on the heating part and focusing on two specific key areas: finished product quality and downtime. Both have a significant impact on operating and maintenance costs if they are not properly considered and implemented.
CD Automation’s recommendations for industrial bakery lines
Here are 5 tips to enable food production facilities to achieve energy efficiency:
Controlling power and temperature with state-of-the-art systems within the food industry
With electronic devices, a life span of up to 10 years can be reached. Considering one or more replacements per year, one can expect to pay a much higher cost of ownership over the life of the machine than with the latest generation of switching devices. Frequent replacement of electromechanical contactors also means frequent downtimes, a cost not to be underestimated. Furthermore, if you add more precise temperature control, improved heater life, and reduced downtime, the choice becomes obvious: using the latest generation of electronic equipment to drive your loads.
Correct dimensioning of power control devices
When dimensioning the device, it is necessary to take into account the line voltage, the heating element and the temperature rating within the control panel. If proper care is not taken, the risk is that the device is undersized and thus operates at or even beyond its limits, resulting in a reduction of its service life.
At CD Automation, we size the power regulator exactly according to your load and add an additional 15% safety margin to cover possible fluctuations in supply voltage, temperatures, etc. All this translates into a typical lifetime of our units of more than 10 years (MTBF). Once you size your units correctly, you have fewer problems to worry about.
Consider the derating curve of components according to the temperature at which they can be used in warmer months
All electronic components are influenced in their function and service life by the ambient temperature in which they are operated. Every 10°C increase in ambient temperature halves the service life of the electronics. The use of forced cooling of the cabinet can avoid premature replacement of electronic units. Our power controllers are dimensioned to operate up to 40°C in continuous operation.
Above this value, the switching capacity of the units will be reduced and a derating calculation will be necessary to determine the correct size of the control units. It is worth measuring the temperature inside the cabinet periodically to ensure that it does not rise.
Pay attention to how the units are fastened and connected within the control panel
It is surprising how many machine failures are caused by weak connections. Electrical connections must be tightened correctly to ensure that the resistance across that connection is as low as possible, ideally 0 ohms. When a connection becomes loose or corroded, it develops resistance. This resistance as current flows dissipates power in the form of heat.
Even a resistor of only 5 ohms can produce more than enough heat to cause the connection itself and the surrounding wires to melt. Faulty wiring can also increase consumption and thus present surprises in your electricity bill. It is recommended to regularly tighten all major connections and fasteners to keep the installation safe and well-functioning.
Carefully consider the effects of fluctuations in the main voltage
Poor quality or fluctuating supply voltage can often cause voltage surges, spikes and fluctuations that can cause damage to components. What can be done? In addition to implementing the above-mentioned points, it is possible to use power units with voltage feedback. These units are able to quickly compensate for voltage increases and supply the required power useful for your thermal process. In this way, you avoid wasting energy or over-temperatureing, resulting in a result that does not conform to production specifications.
