Industrial Energy Systems - Drink Processing Techniques - Assessment Answer

Table of Contents

• Introduction - Page 1
• Answer to Question 1 - Page 2
• Answer to Question 2 - Page 4
• Answer to Question 3 - Page 5
• Conclusion - Page 7

Introduction

Drink processing techniques have aided in storing drinks for a long span of time. Apart from increasing the shelf life of the processed drink, these techniques have also elevated energy consumption in manufacturing processes. This report provides information obtained from the manufacturing process of soft drinks.

The major objective of this report is to provide in-depth knowledge about the manufacturing process, energy requirements, and disposal. The report also highlights over-consumption of energy in each step of the manufacturing process and focuses on how energy consumption can be decreased by using renewable sources of energy. Sustainable methods of manufacturing are also discussed with their usage in soft drink manufacturing industries (Jamalnia et al., 2016). This report focuses on industrial operations involved in soft drink manufacturing.

Answer to Question 1

Soft drinks are an enormously popular beverage worldwide and are present in every region. They are a mixture of carbonated water, sugar, and flavorings. Annual consumption globally is around 34 billion gallons. Despite having a simple list of ingredients, soft drinks are highly consumed and remain popular, especially in the Americas, representing around 25% of the total beverage segment.

To produce such a high quantity, multiple steps are involved in the production cycle:

• Clarification of water
• Filtering, sterilizing, and dechlorinating water
• Mixing of ingredients
• Carbonating the beverage
• Filling and packaging

Clarification of Water

Impurities such as suspended particles, organic matter, and bacteria are removed to prevent degradation of taste and color (Kume & Fujiwara, 2018). This is achieved through coagulation, filtration, and chlorination.

Filtering, Sterilizing, and Dechlorinating

Water is filtered through sand to remove fine particles. Sterilization removes bacteria and organic compounds, and carbon filters dechlorinate the water.

Mixing Ingredients

Ingredients such as sugar and flavor concentrates are pumped into dosing stations and stored in batch tanks, sterilized using ultraviolet rays (Research Gate, 2019). Sophisticated machines ensure correct ratios of syrup and water.

Carbonating

This step is carefully controlled as carbon dioxide solubility decreases with increasing temperature. The CO2 pressure depends on the soft drink type.

Filling and Packaging

Drinks are packed at high speed and sealed immediately (Lima et al., 2018). Bottles are brought to room temperature for labeling and then packed in cartons for distribution.

Energy Consumption

Figure 1: Annual Electrical Energy Pie Chart for a Large Soft Drink Manufacturing Plant

The maximum energy consumption is in refrigeration (27%), followed by air compression (17%), lighting (14%), fluid pumps (10%), and other motors (12%). Other processes consume less energy.

Answer to Question 2

Figure: Sankey Diagram for Energy Consumption in Soft Drink Facility

Refrigeration consumes the most energy. Energy savings can be achieved by sequencing compressors, using high-efficiency refrigeration compressors with VFD controllers, recovering heat from ammonia vapor, and optimizing suction and head pressures.

Air compressors are also significant electricity consumers. They power conveyor jets, drying applications, and pneumatic actuators. Blow dryers can replace air jets to save energy.

Lighting consumes 14% of energy. Warehouses with high-intensity lights can benefit from sensors to dim lights when not in use.

Fluid pumps use 10% of energy to transfer water and soda through factory pipe networks. Minimizing pipe turns reduces friction and electricity usage.

Miscellaneous processes (7%) include fuel for raw material transport, packed cartons transportation, and other factory losses.

Most energy is consumed in these five processes, making it essential to minimize consumption through operational standards across departments.

Answer to Question 3

Beverage manufacturing industries have grown significantly over the last two decades, leading to increased energy consumption. Renewable energy resources must be incorporated in soft drink manufacturing (Almeida et al., 2017). Major energy-consuming activities include:

• Refrigeration
• Cool rooms
• Bottling lines
• Conveyors
• Boilers

Renewable Energy Sources

Solar Energy

Solar energy is free and inexhaustible. It can be harnessed as heat or electricity using photovoltaic systems or concentrated solar power systems. Coca-Cola and Britvic have adopted solar energy to power plants and warehouses, resulting in cost reduction (Karttunen & Moore, 2018).

Biodiesel and Ethanol

Transportation of raw materials and finished products consumes large amounts of fuel. Biodiesel, similar to petroleum-based fuels, is an eco-friendly alternative. It is used in the U.S. for transporting raw materials and processed drinks, reducing transportation costs (Patel et al., 2017).

Energy Reduction Methods

• Regulation and Monitoring of Refrigeration: Refrigeration rooms should be isolated, with automatic doors and continuous monitoring to optimize energy and prevent odors (Abraham et al., 2018). Packed refrigeration systems using CO2 or ammonia are cost-effective.
• Minimizing Water Consumption: Condensate can be reused for washing or sprinkling. Countercurrent washing reduces water usage, and water streams can serve secondary purposes without compromising safety (Alkaya & Demirer, 2015).

Conclusion

Soft drink manufacturing industries have relied on non-renewable energy for decades. The adoption of renewable energy sources such as solar energy and biodiesel has led to a shift toward sustainable manufacturing. Factories and warehouses are increasingly powered by solar energy, and biodiesel is used for transportation. These changes contribute to sustainable development and provide long-term benefits.

References

• Abraham, O.G., Idowu, B.O.O., Barbara, A.U., Veadams, I.E. and Alexander, E.O., 2018. Qualitative Detection and Isolation of Bacteria from Surfaces of Canned Drinks Sold in Ugbor, Benin City. Annals of Science and Technology, 32, 20-25.
• Alkaya, E. and Demirer, G.N., 2015. Water recycling and reuse in soft drink/beverage industry: A case study for sustainable industrial water management in Turkey. Resources, Conservation and Recycling, 104, 172-180.
• Almeida, C.M.V.B., Rodrigues, A.J.M., Agostinho, F. and Giannetti, B.F., 2017. Material selection for environmental responsibility: the case of soft drinks packaging in Brazil. Journal of Cleaner Production, 142, 173-179.
• Jamalnia, A., Yang, J.B., Xu, D.L., Feili, A. and Jamali, G., 2019. Evaluating the performance of aggregate production planning strategies under uncertainty in soft drink industry. Journal of Manufacturing Systems, 50, 146-162.
• Karttunen, M. and Moore, M.O., 2018. IndiaSolar Cells Trade Rules, Climate Policy, and Sustainable Development Goals. World Trade Review, 172, 215-237.
• Kume, K. and Fujiwara, T., 2018. Manufacturing Flexibility Under Uncertain Demand by a Real Options Approach. In Global Value Chains, Flexibility and Sustainability, 161-171. Springer, Singapore.
• Lima, P.M.A.P., Orsoli, P.C., Arajo, T.G. and Brando, D., 2018. Effects of a Carbonated Soft Drink on Epithelial Tumor Incidence in Drosophila melanogaster. J. Pharm. Pharmacol, 6, 240-247.
• Patel, A., Arora, N., Pruthi, V. and Pruthi, P.A., 2017. Biological treatment of pulp and paper industry effluent by oleaginous yeast integrated with production of biodiesel as sustainable transportation fuel. Journal of Cleaner Production, 142, 2858-2864.
• Research Gate, Energy Conservation Opportunities in Carbonated Soft Drink Canning/Bottling Facilities, 2019. Retrieved from https://www.researchgate.net/publication/44288449_Energy_Conservation_Opportunities_in_Carbonated_Soft_Drink_CanningBottling_Facilities

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