FERRERO MANGIMI SPA

Sector: Feed - Sub-fund: production of zootechnical foods

Customer company requirement

The Ferrero Mangimi Group is a historic animal feed production company. Market leader in Italy and abroad, it has three production plants in Italy. The main and historical headquarters is located in Farigliano (CN), the main factory is in Fossano (CN) and the alst, also in terms of time, is that of Sorbolo in the province of Parma.

Express needs:

reduce energy costs.
Carry out an intervention with innovative technologies able to last over time.
Flexibility aimed at supporting the future development of the company, in continuous growth.

It was decided to start with a global energy efficiency intervention at the Parma plant.

Project objective

The detailed project objectives emerged following a detailed energy analysis, detailed and immediately executive, which highlighted some macro interventions including the arrangement of the power distribution MT/BT combined with a cogeneration plant and a series of interventions on air compressors, on engines and lights, always with a view to maximizing current and future energy efficiency. The important use of energy and steam made it opt fotr the installation of a 1400 kW electric cogenerator unit, located outside the plant in a soundproof container, complete with the installation in the field of probes and sensors connected to the integrated system of Aspecindustry control to manage in real time, on the basis of user-defined settings, the generation of electrothermal energy in the correct quantity to always be in a situation of self-production and total self-consumption.

Interventions carried out with the installation of the Aspecindustry system:

Development of the system in "turnkey" mode, as the only operating formula that allows the management of performance and technical/economic results presented during the offer and contract phase, including:

drafting of the (preliminary and executive) electrothermal and energy automation project, able to achieve the objectives and performance envisaged in the business plan phase and to respect the return time of the investment calculated in less than three years.

Complete contruction of the customized cogenerator in soundproofed container made up of an American Cummins engine with an electric power of 1400 kW, alternator, heatsink, chimney with fume elimination and NOx with urea, totalyy silent, electrical and hydraulic systems.

Writing of customized Aspecindustry management software and its commissioning.

Management of the whole bureaucratic process of requesting environmental permits.

Service assistance plan for engine, management and future bureaucracy.

BENEFITS OBTAINED

Electricity requirement coverage 87% approx. Coverage of the heat requirement (hot water and steam) 100%.

Great total energy savings of primary consumption of electricity and steam for the production process.

Very competitive costs of the system thanks to the integrated and total internal vertical construction of the netire cogeneration system.

Use of engines and components of primary brand and very high performance to guarantee high levels of performance and durability of the entire cogeneration group as well as spare parts (the Italia Cummins branch located in Lombardy).

Independent and independent control system, but also manageable in manual and semi-automatic mode, both on site and remotely.

Service assistance contract that totally releases the customer from all the costs of management and maintenance of the system and alarms h 24 7/7 days.

Flexible and open system, always perfectly implementable and integrated with renewable energy systems such as photovoltaic or biomass but also with energy accumulators (specifically with rotating mass technology).

Possibility of interaction of the Aspecindustry system with other industry systems 4.0.

Intelligent and automated amangement of the use and control of the cogenerator and of the entire system and consequent minimum commitment of company personnel.

Total respect of emissions even more restrictive as those of the Emilia Romagna region.

Hight efficiency CAR cogenerator with consequent withdrawal of the white certificates managed by Albasystem on behalf of the customer, thus obtaining the maximum economic advantage.