Driving productivity in Mzuri Sweets from a distance

Mzuri Sweets Ltd. is a major player in the confectionery industry in Kenya. The company manufactures high quality gumballs, bubblegum, candy and lollipops, all under the signature brand, Mr. Berry’s. The company’s commitment towards quality has enabled it to thrive in a market, previously dominated by both foreign and local confectionery multinationals.

In light of the pandemic-induced lockdown, Thermax helped Mzuri Sweets prepare for a proper shutdown and safe restart. Thermax’s technical intervention ensured continuous operation and productivity at the plant amidst the crisis.    

Thermax’s chillers cooling the plant floors

Mzuri Sweets is known for deploying advanced technologies in its manufacturing plant to achieve the best quality production. In line with its commitment towards quality, the company had sought Thermax’s cooling solutions for comfort cooling its premises. Hence, Thermax had commissioned a double effect steam fired vapour absorption chiller at the manufacturing facility in early 2016. The chiller’s performance has been good ever since the commissioning and the company was immensely satisfied with its operation.

Temporary lockdown in response to government guidelines

As the COVID-19 pandemic swept across the globe, the Kenyan government announced a 20-day lockdown across the country. The sudden announcement presented Mzuri Sweets with a significant operational challenge. The company was looking for ways to properly shut down the manufacturing plant – all the while preparing for a quick rebound after the 20 days of inactivity. The immediate crisis pushed the plant operators to quickly find ways of sustaining their operations while mitigating operational risks.

Service via ROSS: Re-imaging chiller monitoring and control

In order to ensure a smooth startup and avoid any mishaps in the future, the plant operator contacted Thermax for proper shutdown of the chiller. The conventional way of shutting down the chiller would have been to visit the site, monitor the chiller parameters, and implement the shutdown procedures.

With travel restrictions and social distancing measures in place, visiting the plant was out of the question. This is when Thermax’s cloud-based chiller monitoring system – ROSS (Remote Online Service Support) proved useful in controlling the chiller while being far away from the site. The capability to remotely monitor the parameters, status, and usage of the chiller ultimately ensured a smooth shutdown and startup at Mzuri Sweets.

Implementing chiller shutdown procedures

After analysing the operational conditions of the chiller, Thermax’s technical service expert communicated standardised shutdown procedures to the plant operator at Mzuri Sweets.

  • Complete dilution of the chiller to bring LiBr to room temperature
  • Isolation of steam inlet and outlet valves to ensure maximum productivity once the plant operations are restarted
  • Breaking chiller vacuum
  • Shutdown of diaphragm valves

ROSS’s assistance in reviving plant operations

After the short-term inactivity, when the plant operations at Mzuri Sweets resumed, our service expert intervened again for a smooth rebound. As the operations began to normalise, Thermax’s assistance towards achieving pre-shutdown productivity at Mzuri Sweets included the following recommendations:

  • Maintenance of inlet cooling water temperature to prevent high scaling and generation of non-condensable gases
  • Regular scheduling cooling tower service
  • Periodical cleaning of water strainers

Shutdown and revival service support benefits

By clearly analysing, communicating, and enforcing the best shutdown and revival practices, Thermax’s service enabled Mzuri Sweets to enjoy the following benefits:

  • Access to the same expertise as on-site services
  • Decreased amount of downtime
  • No loss of production
  • Achieve pre-lockdown productivity when the operations resumed
  • Operational enhancement by means of dilution and maintenance
  • Increased chiller reliability

Combining chiller monitoring technology and service excellence, Thermax has ensured operational continuity at Mzuri Sweets.  The thorough analysis and great co-ordination between the teams from Thermax and Mzuri kept the plant up and running, despite the unavailability of a chiller expert on premises. By leveraging ROSS, Thermax assures excellent service support for continued productivity in industries even in situations of utmost uncertainty.

Thermax’s remote monitoring service prevents downtime and maintains productivity at CBL Global Foods

CBL Global Foods Ltd., manufacturer and exporter of coconut-based products, is a group company of the legendary Ceylon Biscuits Limited in Sri Lanka. The company is known well in the country for its ‘Sera’ coconut milk, organic coconut milk, coconut water and juices. Being a primary exporter of coconut products to Europe & Asian countries, CBL Global Foods Limited has in place a sophisticated plant dedicated to steam infusion and downstream homogenisation process.

Thermax’s chillers at CBL Global Foods

With the island nation implementing stringent legislation and standards for the food industry, CBL Global Foods introduced a few changes to its food processing operations. As a part of the revamp, the company replaced its cooling machinery with two of Thermax’s steam fired vapour absorption chillers each of 98 TR capacity. The chillers cater to the process cooling of coconut milk in pasteurisers and comfort cooling at the plant. Regarding the chillers, “We are glad to record that since their erection from 2015 onwards, the chillers are in continuous operation to cater to the plant’s chilling load and we are satisfied with the efficiency and performance of the machines,” says Gihan Samaraweera, Assistant Engineering Manager at CBL Global Foods. The chillers are connected to ROSS (Remote Online Service Support) and are under constant monitoring by Thermax’s service team.

Spotting potential problem in the chiller

On 17th August 2019, ROSS displayed a temperature deviation in the chiller at CBL Global Foods’ plant. The outlet temperature was at 6.8°C against the designated 2°C. The defect, if left unnoticed, would have led to an inevitable loss of productivity since cooling is an important procedure in coconut milk processing. Our technical service team logged into the chiller and analysed its previous data logs. The ROSS reports traced back the issue to irregular purging and blowdown of the machines. Failure to perform blowdown in the chillers often results in slow down of operations. In addition, the inlet cooling water was sent at a temperature higher than the designated 7.1°C.

The issue was communicated to the operator and was addressed on the same day. Towards the evening of 17th August, the chiller’s outlet temperature was brought down to 1.8°C against a setpoint of 2°C. The temperature deviation possessed the potential to result in a 3-day downtime of the plant’s processes. Detection of aberration in the chiller parameters and identification of the root cause well in advance prevented unwanted downtime and huge maintenance costs to the company. Quick intervention by the service team with accurate information at the right time led to an uninterrupted production process at CBL Global Foods. Speaking on ROSS, “We also like to express our appreciation to their Technical Services team for providing digital services via internet with their innovative and advanced technology. In the past one and a half years, their smart services had helped us maintain 100% uptime of the machines. We are excited and pleased to use this facility and would recommend ROSS to other organisations for using Thermax Absorption Chillers,” added Gihan.

CBL Global Foods having experienced the benefits of ROSS several times and have appreciated Thermax’s Technical Service team for their timely support. ProiCare analytics from ROSS sends automated mails of the daily data logs, fortnight reports, and other alerts, which helps the company maintain a 100% uptime of the machines. Addition of ROSS to the commissioned chillers gives Thermax the opportunity to collect data, check status, predict downtime, recommend solutions and do so much more that industries using chillers never imagined of such a solution. Service with ROSS at CBL Foods Group is another epitome of how Thermax takes customer service to incredible heights.

ROSS – Continuous monitoring with an automated solution

At Thermax, addressing every conceivable factor of customer experience is crucial. Our efforts to offer excellent service coupled with the recent advancements in remote automated solutions gave way to ROSS. It is a system of cloud-based industrial maintenance, which connects installations across the globe to Thermax’s servers. ROSS enables managing and monitoring the chillers with alarms, trend graphs, and reports efficiently. With ROSS, the exact status of the chiller can be monitored anytime, thus offering customer service and chiller maintenance remotely. Machines across the globe can be promptly serviced by engineers remotely at the slightest indication of deviation in its parameters. The system, apart from speeding up the troubleshooting process, completely avoids the chiller’s downtime and call for maintenance.

A new pin on Thermax’s global footprint landscape

Thermax successfully commissioned a 345 TR double effect vapour absorption chiller at Industrias Venado in Bolivia. The company manufactures yeast and gelatine products under well-known brand names, viz. Fischmann and Royal. The chiller operates on natural gas and provides chilled water at 12º C. This chilled water is used for maintaining a low temperature during the fermentation process, thus catering to the process cooling requirement. With this installation, we have commissioned our first absorption chiller in this country. Thermax’s energy efficient chiller is helping the company increase the efficiency and productivity of its process.

Food major opts for Thermax’s boilers and air pollution control systems

A leading manufacturer of nucleotides, lysine and monosodium glutamate (MSG) in Indonesia was a user of coal based chain grate fired boilers across their plants. Thermax was given an opportunity to replace their low-efficiency boilers with a Bi-drum FBC boiler in 2016. Satisfied with the quality and performance of the product along with curbing coal consumption, the customer placed a repeat order for 3 x 35 TPH Bi-drum boilers for its other plants. Thermax also supplied and installed four numbers of Electrostatic Precipitators (ESPs) on their existing boilers to achieve particulate emission norms of <100 mg/Nm3.

Thermax successfully commissioned a biomass boiler for an FMCG major in India

Thermax’s CPRG boiler at Dabur’s katni plant is used 24 hrs a day to make their renowned product Chyawanprash.

PROJECT BACKGROUND

Dabur India Ltd. is one of India’s leading FMCG Companies, building on a legacy of quality and experience of over 133 years,Dabur is today India’s most trusted name and the world’s largest Ayurvedic and Natural Health Care Company. Dabur India is also a world leader in Ayurveda with a portfolio of over 250 Herbal/Ayurvedic products. Dabur’s FMCG portfolio today includes five flagship brands with distinct brand identities Thermax’s association with Dabur is for their two plants Sahibabad and Katni. At Sahibabad Plant,in 2013 Thermax has successfully commissioned a 5 TPH boiler that effectively uses wet herbal waste with 70% moisture which is a residue of their process making of various Herbal products. and continuing the trusted partnership Dabur gave the order for 8TPH for their Katni plant.

Dabur India Katni Plant was a manufacturing unit of Chyawanprash previously now it only produces initial raw material for Chyawanprash then this raw material is transferred to their Sahibabad unit for the final product.

SOLUTION PROVIDED

CPRG 8TPH biomass boiler was proposed understanding the customer’s steam consumption pattern in the process. This plant uses Mustard briquette as fuel that is used for preparing raw material for Chyawanprash. Steam gets utilized for boiling Amla and then it is mixed with ghee to produce initial raw material for Chyawanprash.

BUSINESS PROPOSITION

A CPRG briquette-fired boiler of 8 TPH ensuring energy (steam) delivered at an optimum price leveraging high-end automated biomass boiler installation. Thermax has offered Lambion Reciprocating grate technology.Reciprocating Grate utilizes successive oscillation of grate linkage for the continuous movement of fuel; alternate movement of grate blocks pushes the fuel in the distinct combustion zones of a grate to ensure high steam to fuel ratio.

 

 

POSITIVE IMPACT

  • Optimum Cost-Effective Steam Price
  • Ensuring consistent quality at the right price
  • Guaranteed Boiler Uptime
  • Efficiency throughout the Product Lifecycle

Thermax Process Heating Solutions

A strategic business unit offers packaged boilers, thermal oil heaters, waste heat recovery boilers, hot water, and air generators. These are available in modular construction as a standard package configuration or a custom design for specific requirements. Innovated by a strong R&D that focuses on customer applications, we
offer a range of heating systems designed to combust a wide range of solid, oil & gas fuels including biomass and heavy liquid fuels.

THERMAX MADE IT POSSIBLE! UP TO 45% FUEL COST SAVING USING 100% BIOMASS FIRING

Introduction

Thermax is committed to ‘Conserving energy and preserving the environment’, two areas vital for the world. We support business establishments to be more energy efficient and environment-friendly.ITC Group a multi-business conglomerate is one such customer for Thermax. They have various manufacturing plants across India and one of them is at Ranjangaon Pune MH. This food production unit manufactures instant noodles and potato chips.

PROJECT INSIGHTS

In 2012 ITC was looking for expansion with a cost-effective fuel solution and was keen to have 100% biomass-fired unit, yet the biggest challenge here was maintaining steam-fuel ratio as the calorific value of fuel i.e. biomass briquettes changes drastically.

There were three main criteria’s for this project :

  1. UNINTERRUPTED STEAM SUPPLY
  2. FAST RESPONSE TO FLUCTUATINGLOAD”
  3. HIGH EFFICIENCY

INNOVATIVE SOLUTION BY THERMAX

A heating system is the heart of any food processing unit. ITC group partnered with Thermax for a reliable solution which consisted of a 14 TPH boiler (CPRG 140) with economizer and air pre-heater ensuring higher efficiency and uptime for high-pressure steam requirements in the chips and noodles frying process.

RECIPROCATING GRATE

Reciprocating Grate utilizes successive oscillation of grate linkage for the continuous movement of fuel;
alternate movement of grate blocks pushes the fuel in the distinct combustion zones of a grate.

Advantages

  • 100% combustion
  • Highest uptime and efficiency
  • Low emission

To ensure steam to fuel ratio of 5.0 Thermax has offered Lambion Reciprocating grate technology. Thermax has Licensed Lambion technology that has over 100 years of experience in biomass firing solutions. The grate offers progressive combustion with distinct combustion zones making it ideal solution for biomass firing up to 60%
moisture content.

The Adaptation of an efficient boiler system from Thermax and the change in fuel from FO (furnace oil) to biomass briquettes helped ITC to achieve these challenging results with just 3-4 people managing the complete plant operations.

  1. STEAM TO FUEL RATIO 5.0
  2. FUEL COST SAVING UP TO 45%
  3. SPM LEVEL AS LOW AS 28 PPM

Thermax welcomes another happy customer in its fold

THERMAX HELPS BUDHANI BROS WAFERWALA TO SAVE FUEL COST BY 20%

Introduction

Budhani bros waferwala trusts thermax for their potato chips frying process for the last two decades sharing a
journey of quality, reliability , and sustainability.

The famous food major is associated with Thermax since 2003 from the time they introduced a fully automatic system for chips frying and purchased 1st Thermic fluid heater of 10 lac Kcal/hr. The association since then has resulted in a trusted bond that made Thermax an obvious choice when they were expanding in 2016 and purchased second Thermopac of 25 lac Kcal/hr.

THERMAX’S THERMIC FLUID HEATER–THERMOPAC-OFFERS

  • Fuel flexibility
  • Minimal maintenance
  • Best in class efficiency

IN CONVERSATION WITH MR. ARVIND BUDHANI
OWNER BUDHANI BROS

He refers to their mission of “ensuring optimum utilization of resources by integrating latest technology to provide the best quality and appropriately priced snacks to everyone, everywhere ” explaining Thermax’s thermopac have been an integral part of the growth of small household business venturing into a business empire.

THERMAX’S THERMIC FLUID HEATER OFFERS ENERGY SAVING UP TO 20%

The well-known quality of these chips comes from the sustained crispiness, size,and color. Thermax’s Thermopac helps maintain these crucial parameters with an uninterrupted hot oil supply and consistent temperature of the oil with precision up to +/-1 degree C at the fryer. The process is continuous and any small deviation in the temperature can ruin a complete batch of final product.

Customer proudly mentions that they have no standby unit thanks to the efficient and reliable thermopac and real-time services maintained over a period of time by Thermax Ltd.

Thermax Limited continues to be a trusted business partner for Budhani bros.

GREEN STEAM SUPPLY AVT NATURAL PRODUCTS LTD.TIPTUR

Thermax process heating solutions reduced carbon footprint- the plant is equivalent to carbon capture by 3 LAKH TREES!

PROJECT BACKGROUND


AVT is a public limited company promoted by AV Thomas Group. AVT Natural Products Ltd (AVT NPL) is a venture promoted, as a strategic diversification from the traditional plantation business. Operating in line with its corporate signature, the company specializes in the extraction of colors and flavors from a natural source. The Group consists of diversified Business in Tea, Rubber, and Consumer Products viz. spices, food ingredients, and healthcare products.

AVT identified with Thermax on the shared belief towards dedication to the customer satisfaction and adherence to highest quality standards and gave us the contract for a Greenfield Boiler Project.

SOLUTION PROVIDED

ComBlocUltra Biomass Boiler Model: CBRG100-Ultra with Reciprocating Grate using Lambion, GmbH Technology

CA strategic business unit offers packaged boilers, thermal oil heaters, waste heat recovery boilers, hot water, and air generators. These are available in modular construction as a standard package configuration or a custom design for specific requirements. Innovated by a strong R&D that focuses on customer applications, we offer a range of heating systems designed to combust a wide range of solid, oil & gas fuels including biomass and heavy liquid fuels.

BUSINESS PROPOSITION

Thermax proposed a briquette-fired boiler of 10 TPH@14 kg/cm2(g) ensuring energy (steam) delivered at an optimum price leveraging high-end automated biomass boiler installation. Combloc – a compact, plug & play modular construction boiler with fully automatic operation ensuring high efficiency. Thermax has offered OPEX proposition with BOO (Build-own-operate) model ensuring highest uptime at all time.

BOILER AT A GLANCE

  • Model: CB Ultra- 100/14
  • Capacity: 10 TPH (F&A 100°C)
  • Type: Hybrid Water & Smoke Tube design Boiler with automated,air-cooled reciprocating combustor system of Lambion (German Technology)
  • Design Pressure: 14 kg/cm2
  • Operating Pressure: 9.5 kg/cm2

POSITIVE IMPACT

  • Optimum Cost-Effective Steam Price
  • Guaranteed Boiler Uptime & Efficiency throughout the Product Lifecycle
  • A significant decrease in SPM emissions
  • Dedicated biomass fuel supply chain
  • Ensuring consistent quality at the right price

Thermax supports ITC’s green initiative by offering 100% biomass-fired boiler ensuring cost saving up to 45%

Introduction

Thermax is committed to ‘Conserving energy and preserving the environment’, two areas vital for the world. We support business establishments to be more energy efficient and environment-friendly.
Our legacy is enriched with the green effect projects for which we are the first choice for some of the global brands in the word. ITC Group which holds a market capitalization of 50 billion USD with a turnover of 8 billion USD crediting to their robust portfolio of traditional and Greenfield businesses is one such esteemed business alliance for Thermax process heating solutions.
The multi-business conglomerate encompasses various manufacturing plants across India and one of them is at Ranjangaon, Pune MH. This food production unit manufactures instant noodles and potato chips. A heating system is the heart of any food processing unit and ITC group partnered with Thermax for a robust heating system. ITC group’s association with Thermax was cemented with the commitment to supply a
heating system to fulfill their steam requirement for which three FO (Furnace oil) fired boilers were commissioned for the same.

Project Insights

In 2012 ITC was looking for expansion and was keen to have a greener, cost-effective fuel, they decided to go for 100% biomass briquettes fired boiler from Thermax. There were three main criteria’s for this project – 1) Uninterrupted steam supply, 2) fast response to fluctuating load and 3) high efficiency. As ITC was keen to have 100% biomass-fired unit the biggest challenge was maintaining steam-fuel ratio as the calorific value of fuel i.e. biomass briquettes changes drastically due to the variation in moisture content, bulk density, ingredients of briquettes etc. Thermax understood customer’s requirement and proposed a fully automatic CPRG (Combipac Reciprocating Grate) boiler with automatic fuel feeding system, air pre-heater, and economizer to ensure best in class efficiency with suitable equipment.

Innovative solution by Thermax

The solution provided by Thermax-CPRG (Combipac reciprocating grate) boiler which can provide 14000 kg per hour steam for high-pressure steam requirements in chips and noodles frying process. The boiler is designed to respond to sudden load changes which are typical for food processing industry. Thermax has proposed boiler with a unique offering of “moving floor” which saves space and has automatic fuel level controller. From the moving floor, the fuel is then sent to fully automatic fuel feeding system comprising of dosing bin and multi-screw fuel feeder. To ensure steam to fuel ratio of 5.0 Thermax has offered Lambion Reciprocating grate technology. Thermax has technology tie-up with Lambion who has over 100 years of experience in biomass firing solutions.

Reciprocating grate

Reciprocating Grate utilizes successive oscillation of grate linkage for the continuous movement of fuel; alternate movement of grate blocks pushes the fuel in the distinct combustion zones of a grate. This gives toppling action to the fuel particle and hence ensures complete combustion. This grate offers progressive combustion with distinct combustion zones. Relative motion between fuel bed and grate helps to deal with poor fuels up to 60% moisture content.

Energy efficient and low emission operation

High efficiency is an important aspect of achieving an energy efficient operation process of the chips and noodles frying process. Thermax offers both air pre-heater to preheat the combustion air up to 150°C and economizer ensuring the water is preheated up to 120° C. CPRG offers advantages like 100% combustion, highest uptime and efficiency and low emission. Thus the fuel consumption during steam generation is reduced drastically, and hence compared to FO fired boilers the fuel cost saving is 45%*

Positive impact

The flue gas exit temperature is at 100-120° C. The boiler achieves SFR of 5 and ash percentage is as low as 14-15%. The SPM level is as low as 28 ppm. In order to achieve optimum fuel consumption, an O2 controller is integrated into the plant. An oxygen probe measures oxygen continuously and compensates changes in air temperature and air pressure automatically. This optimizes the efficiency of the boiler and reduces the negative environmental impact at the same time.

Continues automation and reliability

The high degree of automation in the steam boiler plant provides comfort and safety to the boiler operator who can see complete process of the boiler from a system linked computer screen. The controller can also manage the equipment and other parameters like fuel feeding, feed water section, combustion manager, and flue gas section, making the boiler unit an automated, timely and reliable solution. This makes the entire plant operation automated and the process can be managed by limited no of people.

The result

The Adaptation of an efficient boiler system from Thermax and the change in fuel from FO (furnace oil) to biomass briquettes helped ITC to save fuel cost by 45%*. The PLC (programmable logic controller) system
continuously monitors the performance of boiler thus
ensuring safety and optimum performance. The proven
construction of combipac together with appropriate plant
equipment and reciprocating grate technology ensures
continuous and high steam quality for chips and noodles
frying process. Thermax’s service team ensures optimum
plant settings, a constantly high efficiency, very low
emission and longer life of the entire plant with their
regular maintenance services.

Thermax Chillers Installed At A Food & Beverages Major In Saudi Arabia

The deployment of Thermax chillers in the potato frying process for a Food & Beverages major is one of the pathbreaking applications developed by the Absorption Cooling team.

After tasting success at its pilot manufacturing facility in India, the customer has partnered with Thermax to replicate this technology at several of its locations across the globe, the latest one being in Saudi Arabia. Here, Thermax successfully commissioned two ultra-low pressure vapour driven absorption chillers of 1000 TR each. These chillers help conserve water wastage by capturing the vapour released during the process of potato frying through a fan and further channelised through a duct for providing chilled water at 7ºC. This water is used for both process and comfort cooling requirements of the customer, such as air conditioning and refrigeration.

Being the largest capacity chiller supplied in the ultra-low category by Thermax, to date, this technology has resulted in significant power savings of 4500 MW and reduction of carbon footprint by 9,830 tonnes per year, equivalent to planting 5,22,240 trees.

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