Buhler Energy Solutions.
Energy-efficient solutions for chocolate and cocoa production.
Life survives on energy. Whether it’s the energy we need to commute to work in the morning, or the vibrational energy that holds the universe together. Never before has energy become such a hotly debated subject that now resonates from board tables of the world’s industrial confectionery producers. The difference now however, is that the energy debate is being driven hard by the consumer. Consumers are becoming increasingly more aware of, not only their own responsible use of energy, but now, their sites are starting to home in on the food manufacturer’s ethical use of energy as well.Consumers are increasingly more demanding in their need to feed their thirst in knowing how products are manufactured and whether they have been produced ethically, as we have seen with the rise of fair trade and sustainability trends. But now, a major new trend is on the horizon and confectionery company executives are right to start the debate. Both industry and governments are keen to play their part in increasing the efficiency of businesses and cutting down waste and moreover, to be seen as an ethical producer with strong values towards the future of the environment. This trend is set to stay, and it’s ultimately a good thing.
Production is no longer an isolated process and energy ceases to be a commodity, energy has now become a consumer issue. Due to it’s inexorable rise in price in the last decade, energy is so valuable, that by saving it and using it economically, some considerable costs can be saved and moreover, powerful marketing stories can be sung from the rooftops. Take for example if all the cocoa beans from around the world where processed with Buhler’s new improved ethical shell burning technology, combined with savings earned from Buhler’s detailed energy audit, it could save enough money to build 13,000 schools in Africa. (Equiv. Euro 130 million. It costs euro 10,000 to build a three class room school in Angola).
According to the ICCO, 3.56 million tonnes of cocoa beans were harvested in 2009. From that, 200 euro million is spent by the chocolate industry on the bean cleaning, roasting, debacterizing, winnowing and grinding of the beans. From this, with Buhler’s new technology and energy audit, as much as 65% of the energy bill can be saved in total. “It’s a considerable amount of money,” says Thomas Bischof, Product Marketing Manager, Bühler AG, “not only in terms of eventual increased profits for the producer, but also a major benefit for the environment. The money reaped in savings can to be used elsewhere, in an ethical way, for example in fair-trade projects. Everyone ends up a winner. Manufacturing is now, not just about producing great tasting chocolate, but about how we are perceived by the consumer. Here is an opportunity to be seen as an environmentally friendly producer with low energy costs and CO2 emissions. These things really matter to consumers now and of course the savings are huge and chocolate producer’s return on investment is rapid due to high energy costs.”
Buhler is heading the field of energy saving initiatives with specifically designed energy saving equipment, and an impressive line up of engineers and technicians trained to carry out an advanced energy audit. Chocolate producers can opt for a free audit of their manufacturing processes and a total energy audit can be carried out with Buhler engineers. “We get some real surprises from our customers and a few raised eye brows,” says Thomas Bischof. “For example, our engineers normally find that heat recovery systems in roasting can waste as much as 15% in energy, our team also tend to unearth a 5% saving in de-bacterizing and another 10% with a new intelligent combination of energy streams. That’s just for starters! There is a lot of work to be done. Our energy audit nearly always reveals exciting opportunities and it’s a very positive process for our customers to take a step back and let us review their costs for them. Of course it’s entirely up to them if they wish to take us up on the energy efficient solutions that we recommend.”
Buhler’s energy audit starts by analysing the current situation and defining measures for improving efficiency. Guidelines are recommended for implementation, costs are audited and pay back time is produced. Thorough checks would also be carried out to check that energy that saving targets are achieved.
Over 500 million euros is spent in energy on the total process for the production of chocolate (cocoa liquor to moulded chocolate) world-wide. A further 10% can also be saved easily on the whole production process and that would equate to another 50 million euros. The Victoria Climié Charitable Trust builds and funds schools in the Ivory Coast that can run a school at Euro 23,000 per annum. The over all saving is enough to keep 217 schools running in the Ivory Coast for ten years.
An audit, combined with investments in Buhler’s revolutionary shell burning technology that utilises the energy from the shell that would otherwise have been a waste product, sets the pace for a brand new ‘energy rush’ that will dramatically influence the shape things to come.
