Crispy Crisp

The waste was reduced from 700kg to 30kg resulting in overall savings of £10k per start-up.

EnerTherm Engineering Ltd saves energy and waste in the food and processing industries. Our client Walkers operates a significant crisp production, where large production lines are capable of delivering 3.2 ton per hour of crisp, the equivalent of 1 million bags of crisps per day! When the crisp is out of spec and is rejected from the production line, waste quickly accumulates, which means a big problem for companies.

Walkers came to us with a problem they had during the line start-up, which created a significant amount of waste, 700 kg, in fact, due to the moisture not being in spec. We took the problem and created an optimisation method based on data captured during the line-start up.

One of the critical Key Performance Indicators is the moisture of the crisp. If the crisp moisture is too wet or dry, it will affect the shelf life and the taste of the crisp.

We created an optimisation method based on capturing data during the line start-up. This included process control algorithms being altered to improve the line responsiveness. A number of control loops were also turned over a 4-day period to reduce the time to bring the line back into control and reduce the start-up time by 14 minutes. As a result, the waste was reduced to 30 kg and 180m3 of gas was saved during the line start-up.

A production line will typically carry out around 10-20 start-up a week, resulting in overall savings of £10k per start-up.

EnerTherm Engineering is based at the Allia Business Centre in Peterborough and focuses on solving problems related to production issues, non-optimal plant operation and where energy usage or waste is it at the heart of the customer’s focus.

Our multi-skilled team consists of engineers, scientists and consultants that have the ability to evaluate, troubleshoot, design/redesign equipment and improve process efficiency. Our work ethos follows the 6 Sigma principle, DMAIC: Define, Measure, Analyse, Improve and Control.

Let's Talk About Your Project

François Pierrel

Hi, my name is François and I am passionate about solving process engineering problems. Over the years, I have developed a number of process equipment and control systems which have had significant impact into reducing energy usage, waste and impact on the environment. My business ethos is to always get to the root cause of problems and data analysis and modelling is always at the fore front of any project we undertake.

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