«ZOLOTYY KOROVAY». Pilotnyy proyekt z enerhetychnoyi modernizatsiyi u promyslovosti

1. ZOLOTYI KOROVAI, Ltd. is among
the biggest bakeries in the Zhy-
tomyr Oblast. The company pro-
duces bread, bakery and confec-
tionery goods.
The technological manu-
facturing process envisages cer-
tain successive stages. Flour as
the key raw material is received,
stored in appropriate condi-
tions, bolted and transported
to the production shop; there it
is metered and mixed with liq-
uid components. The prepared
dough products are proofed in
specialized proving cabinets, cut,
steamed and baked. The ready
products are packaged for deliv-
ery and distribution.
The enterprise uses natural
gas and electricity for its produc-
tion needs.
About the Company
commissioned by the German
Government in political part-
nership with the Ministry of
Economy of Ukraine has be-
come another yet impetus
towards more efficiency.
St a r t in g in O c t o b e r
2018, the team of national
and international certified
energy auditors held the en-
ergy efficiency audit and in-
vestmentgrade audit of the
enterprise according to the
standard ISO50002, types 2
and 3. The audits resulted in
a range of measures aimed
at reducing costs associat-
ed with energy resources
and respectively, production
costs. The enterprise priori-
tised the range of measures
opting first-hand for optimi-
sation of burner equipment
and lighting equipment, and
ZOLOTYI KOROVAI, Ltd. ac-
tively implements techno-
logical process optimization
measures to ensure a more
efficient use of energy re-
sources. The par ticipation
in the Advisory Services for
Energy Efficiency in Com-
panies Project implemented
in Ukraine by Deutsche Ge-
sellschaft für Internationale
Zusammenarbeit (GIZ) GmbH
Path to Success
Establishment date
Location
Industry
No. shops
No. working shifts
Working shift duration
Staff
Output
1981
Zhytomyr
Bakery
3
2
11,5
614
9 994
hours
tons/year
Electricity
Natural gas
Total emissions
1 255,14
1 440,59
3 851
1 154,95
1 343,54
3 577
MWh
m3
tCO2eq
/year
2018 2019
Indicators
Review
Pilot Projects
on Energy Modernisation
in Industry
ZOLOTYI KOROVAI,
Ltd.
МІНІСТЕРСТВО ЕКОНОМІКИ УКРАЇНИ
CO
M
PA
N
Y

2. Energy efficiency measures were
implemented in line with energy
audit opinions and recommenda-
tions. For cost-saving purposes
some works were performed by the
enterprise itself with specialised
companies involved in certain indi-
vidual works.
Energy Efficiency
Measures
also started to modernise its
energy consumption moni-
toring system. Besides that,
owing to participation in the
Project baker y employees
were able to attend trainings
and acquire new knowledge
about energy efficiency.
Calibration of Boiler and
Oven Burners
Photo:
The manufacturing processes at
the plant involve technological
equipment with substantial heat
energy consumption rates: tunnel
ovens and boilers with combustion
chambers fitted with burners using
natural gas. Energy consumption
volumes are directly linked to the
efficiencyoftheaboveinstallations.
Whilethecombustionchambersare
of closed type, it is nevertheless
necessary to regularly monitor air
inflows in order to ensure proper
fuel-to-combustionairratio.Thera-
tio and hence, the efficiency of fuel
combustion,isexpressedviatheex-
cessairfactor,α.Therecommended
non-dimensional α value is within
the range between 1.05 and 1.15.
Anyhighervalueindicatespresence
of excess air that will require more
natural gas for heating.
The fine-tuning of boiler
and oven burners can optimise
fuel-to-air ratio in the combustion
chamberandconsequently,provide
for a more efficient energy use.
To implement the measure,
the enterprise subcontracted a
specialised organisation that car-
ried out necessary measurements
and burner adjustments.
In the scope of the event a
total of 15 burners in 4 boilers and
10 gas-fired ovens were fine-tuned.
Before the fine-tuning, the α ratio
was around 2.4 in average; after
the measure it was brought down
to statutory value of 1.15. That
increased the energy efficiency of
boilersby3.8%andofovens,by9%.
The total natural gas consumption
was reduced by 97 thousand m3
a
year. The savings from the measure
amountedtonearlyUAH 640 thou-
sand/year.
Duration of procurement procedure
Duration of implementation
Implementation period
Implementation costs
Nat. gas consumption
before implementation
after implementation
Nat. gas consumption savings
Savings from implementation
Simple payback period
Emission reduction
0,5 month
1 month
2018
446 000
1 440,59
1 343,54
97,05
639 912
8 months
182
UAH
thousand m3
/year
thousand m3
/year
thousand m3
/year
UAH/year
tCO2eq
/year
Indicators
Calibration of Boiler and Oven Burners

3. Lighting Modernisation
Lighting modernisation remains
among the most popular energy
saving measures. While rather
simple and inexpensive, it never-
theless allows saving electricity
due to transfer to more efficient
light sources. With a view of the
mentioned benefits the enterprise
carried out modernisation of exter-
nal and internal lighting of three
shops: the bread, the bakery, and
the dispatch (delivery) one. For this,
123 flood lights with 10, 50 and
100 Wpowerconsumptionand156
light fixtures with 27, 36 and 40 W
consumption for 3 m and 6 m-high
ceilings were bought. Costs of ca-
bling for them were minimal as the
existinginfrastructurewasused.All
theworkswerecarriedoutwithour
own resources.
The replacement of the existing
light sources with new (LED-base)
ones reduced the total power
consumption of the lighting sys-
tem 2.3 times, from 49.98 kW to
21.6
kW). That allowed annual
electricity savings of 117.9 MWh,
or almost UAH 2254 thousand in
monetary equivalent. The results
wereevaluatedbasedonelectricity
bills received.
By early 2021, 84% of the en-
terprise-wide lighting system was
modernised. This allowed to not
only save of electricity costs but
also to improve labour conditions
owing to better lighting of produc-
tion facilities.
Duration of implementation
Implementation period
Implementation costs
Energy consumption
before implementation
after implementation
Energy savings
Savings from implementation
Simple payback period
Emission reduction
1 year
2018 – 2019
88 100
207,41
89,48
117,93
224 544
5 months
108
UAH
MWh/year
MWh/year
MWh/year
UAH/year
tCO2eq
/year
Indicators
Introduction of Energy Monitoring System
Monitoring of energy resource
consumption is a mandatory con-
dition for systemic energy effi-
ciency upgrades at the enterprise.
It allows identifying the efficiency
of energy resource use and pro-
vides the basis for development of
required energy saving measures.
The commercial and techni-
cal metering devices available at
the plant did not allow receiving
full-scale information for energy
efficiency indicators determina-
tion.
The technical metering of
gas and electricity was only done
partially on only five out of the six
production lines. Moreover, data
gathering was not done in a cen-
tralised way.
This can be solved by build-
ing an integrated system, which
would provide for a more precise
identification of energy efficiency
parameters of all the production
processes and for assessment of
results of implemented measures.
With support from the Advi-
sory Services for Energy Efficiency
in Companies Project a concept of
energy monitoring system was de-
veloped during the first phase. For
this, production sites with meter-
ing equipment already installed
were analysed and those in need
of additional metering devices
identified. The key objective was
to integrate the existing meter-
ing points with new ones into a
wholesome automated energy
monitoring system. To implement
the concept, necessary equip-
ment – the automated worksta-
tion of monitoring system opera-
tor, 5 loggers and 5 GPRS routers,
6 power meters and 6 voltage
transformers – was purchased.
The enterprise has committed to
buying additional 4 gas meters
and 2 heat meters.
All in all, the measure will
provide the enterprise with new
possibilities of uninterrupted
control, determination of energy
consumption dynamics and time-
ly mitigation of any deviations as
well as of assessment of energy
efficiency parameters of the pro-
duction cycle, also with a view of
implemented measures.
Lighting Modernisation
Photo:
Lighting Modernisation
Photo:

4. In modern situation manufactur-
ers have to focus their employees
onto energy efficiency and pro-
vide them with necessary knowl-
edge on the topic. The enterprise
fully employs this possibility, par-
ticularly owing to participation in
the Project on Advisory Services
for Energy Efficiency in Compa-
nies.
A specialised training was
conducted for the bakery staff
on the topics of Ventilation, Air
Conditioning and Heating Sys-
tems and Burners and on Energy
Monitoring.
Given the implementation
of the energy monitoring system
also requires appropriate staff
qualifications, employees were
trained to set up the system and
use its potential based of JCEVis
software package. Thanks to ob-
tained knowledge the employees
will now be able to use software
services to generalise and visual-
ise the data on energy saving at
the enterprise.
Staff Training
The company does not stop there
and plans to implement other
measures, including on equip-
ment optimisation. Specifically, a
possibility of improving operation
of the compressed air system is
considered. This will include the
replacement of air compressor to
reduce the installed capacity of
compressor equipment by 35 kW.
Such a modernisation will help
the enterprise to additionally
reduce its electricity consump-
tion by 145.25 MWh/
year and cut
emission volumes by 132 tСО2eq.
By preliminary estimates, the sim-
ple payback period of the project
will make 1.1 year.
The works on energy con-
sumption monitoring system
implementation continue. Spe-
cifically, the rolling out of ful-
ly-fledged system will allow as-
sessing results from the already
implemented energy efficiency
measures and make plans for new
ones.
Company’s Plans for the Future
© GIZ 2021
Pilot Projects on Energy Modernisation
in Industry 01004, Кyiv
16b Antonovycha St.
T: +38 044 594 07 60
F: +38 044 594 07 61
I: www.giz.de/ukraine-ua
www.eeplatform.org.ua
Fb: www.facebook.com/energyefficiency.ua
Total
energy savings
Indicators
7,5%
Investments in the measures paid back in 7.5 months and save
the company more than UAH 864 thousand a year.
It is worth noting the additional benefits of the implemented
measures. Equipment calibration and modernisation of the
existing systems have improved technological processes.
The training events allowed updating knowledge and increasing
the professionalism of employees on energy efficiency matters.
The energy efficiency measures resulted in 7.5% reduction of energy
resource consumption at the enterprise. This brought down the pro-
duction costs and cut GHG emissions thus lowering the environmental
impact.
Cumulative Results
•
•
•
Total energy savings
Total reduction of emissions
Total cost savings
Investments
1 020,54
290
864 456
534 100
MWh/year
tCO2eq
/year
UAH/year
UAH
«In order to be competitive, we have to
control our energy consumption and take
measures to reduce the share of energy in the
production cost»
Oleksandr Verbytskyi
Deputy Director
Calibration of Boiler and
Oven Burners
Photo: