Significant cost reduction through small changes

Bremerhaven student develops energy-saving measures for Starke Bäcker KG

High energy prices are not only a problem for private households, but also for many companies. Profits are significantly reduced, especially for industries whose consumption is very high due to production. As part of his Bachelor's thesis in the Engineering programme at Bremerhaven University of Applied Sciences and on behalf of the management consultancy Lixcon GmbH & Co. KG, Ahmad Elouli examined the question of how a large bakery can reduce its energy consumption. If the company were to implement all the recommendations, it could probably save more than 35,000 euros a year.

Ahmad El Chouli studied Maritime Technologies in Bremerhaven, specialising in engineering. He came into contact with the microgrid while working on a project during his studies. The university has been producing green hydrogen there for several years. ‘As part of the project for a partner university in Bangkok, we investigated whether a microgrid could also be implemented there. We came to the conclusion that it wasn't worthwhile for them. But I was very fascinated by this project. It made me realise that I would rather deal with energy in general instead of just focusing on maritime energy,’ says El Chouli. He was given the opportunity to do this as part of his bachelor's thesis. For Lixcon GmbH & Co. KG, he went in search of energy guzzlers at the industrial bakery.

Electricity and gas are significant cost drivers for bakeries. The ovens and cold stores require a lot of energy. Added to this are factors such as machinery and lighting. Rising energy prices due to the war in Ukraine and the conflict in the Middle East are cutting into profits. This is causing many companies to think about increasing their energy efficiency - including the Starke Bäcker KG bakery, about which Ahmad El Chouli wrote his bachelor's thesis. ‘The customer already had measurement technology for electricity and gas consumption, but didn't have time to look into it themselves,’ says the graduate. 

To carry out his analysis, Ahmad El Chouli used three methods to identify energy efficiency measures. Firstly, he compared the technical status of the company with what is recommended in the relevant literature. This enabled him to work out which measures had already been implemented. He then used the measurement system to create an energy flow diagram. This shows the gas and electricity consumption of individual systems. The data can be used to identify the areas for which measures are particularly useful. ‘Of course, it's most worthwhile to start with the systems that consume the most energy. Energy efficiency increases of just a few per cent can result in significant cost reductions,’ says El Chouli.

The third method was the development of a so-called load profile analysis, which was discussed in the lectures by Prof Dr Carsten Fichter. This allowed Ahmad El Chouli to apply what he had learnt directly. This involves determining the base load, the medium load and the peak load. ‘The base load is the constant power that is always present. For example, because the fridge runs at home even when nobody is there. The medium load does not occur continuously, but regularly. The peak load is the highest power, but rarely occurs,’ explains El Chouli. A load profile is recorded by an institution such as the municipal utility company. This load profile records electricity consumption at 15-minute intervals over the course of a year and provides 35,040 measured values. This data can be used to analyse operating behaviour in order to shift loads as required. In this way, costly peak loads can be avoided.

With the help of his analyses, Ahmad El Chouli was able to identify a number of measures, some of which are easy to implement and yet effective. For example, one of the electric heaters in the rack dishwasher could be switched off, which, according to calculations, could save around 2,500 euros per year. Adjusting the ventilation system to the shift times could also save a small amount each year without requiring a great deal of effort. The energy efficiency measures with the greatest savings potential are initially associated with investments. The old lighting system is soon to be replaced by a new one with energy-saving LEDs. According to calculations, this could save the company around 10,500 euros a year. And a major refurbishment could significantly reduce costs even further. ‘The bakery is planning to modernise its ovens in the coming years. This could involve converting them so that they can recover the vapour heat from the ovens and use it as a flow for the heating system, for example. This has the potential to save up to 23,700 euros a year,’ explains El Chouli.  However, not all measures that would be possible in principle are worthwhile for the company. These include the construction of a combined heat and power plant (CHP), which uses gas to generate electricity and heat. ‘The investment costs for a combined heat and power plant are high, but electricity is produced at gas prices, which is generally cheaper. Ultimately, this investment would not have paid off for the large bakery. However, there are applications where it is worth using it, such as in the swimming pool, where heat is constantly available all year round,’ says the graduate.

Ahmad El Chouli now has his degree in his pocket and works for his client, Lixcon GmbH & Co. KG. The company advises its customers in the areas of energy, the environment, IT security and occupational safety. New and exciting topics are always landing on his desk. His degree programme prepared him well for this: ‘The Maritime Technologies degree programme offers a strong practical focus, especially through the project work, where I learned a lot. The lecturers are committed and manage to arouse interest in the topics.’

The specialisation ‘Maritime Technologies - Marine Technology - Wind Energy - Marine Energies’ of the Engineering degree programme deals with the sea as a versatile energy source that should not be underestimated. Students create an individual specialist profile in marine technology, wind energy or marine energies according to their own interests and choose between a more mechanical or more electrotechnical specialisation. Interested students have until 15 February to apply for a place on this and other Bachelor's and Master's degree programmes. All information can be found at www.hs-bremerhaven.de/studium.