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Effeffe Pet Food

Power Generation for Effeffe Pet Food

Power Generation

Customer Effeffe Pet Food

Where Pieve Porto Morone (PV)

Solution Power generation

Sector Industrial

        
          In terms of eco-efficiency, Cefla not only supported Effeffe Pet Food in the design, supply and installation phases, but also carried out an initial analysis of the overall energy consumption of the plants, completing a project characterised by optimised performance in terms of consumption.

Strengths

Customised solution

Cefla has designed and built a high-efficiency cogeneration plant, customised to meet the specific energy requirements of Effeffe Pet Food, ensuring optimal integration with existing production processes.

Energy efficiency

The plant allows for the simultaneous production of electricity and heat, improving overall efficiency and reducing energy costs.

Environmental sustainability

By recovering thermal energy from the engine circuits, the system contributes to reducing CO₂ emissions, in line with the company's sustainability objectives.

Key Numbers

2.151 kW

Power introduced with fuel

1.237 kWt

Recoverable heat output

507 kWt

Hot water heat output

447 kWt

Steam heat output

Background

Effeffe Pet Food is an Italian company with over 30 years of experience in the production of pet food. Growing demand for high-quality products and a focus on sustainability have driven the company to invest in innovative energy solutions to improve the efficiency of its production processes.

        
          Effeffe Pet Food boasts large-scale production with 3 extrusion lines and over 60,000 tonnes of annual capacity. This is why it has decided to invest in improving its energy eco-efficiency with Cefla.

Challenges

Optimisation of energy consumption
Reduce energy-related operating costs while maintaining high production quality standards.
Environmental sustainability
Minimise environmental impact by reducing emissions and adopting clean technologies.
Technological integration
Implement an advanced energy system without interrupting existing production activities.

Project Tasks

Cefla provided a turnkey solution, including the design, supply, installation and commissioning of a high-efficiency cogeneration plant. The plant was integrated with Effeffe Pet Food's existing systems, ensuring a smooth transition and improving overall energy efficiency.

Implementation

Cefla designed an EASYPOWER_G316 GS cogeneration plant for Effeffe, running on natural gas, with heat recovery from the engine cooling circuit and combustion fumes.

The plant, consisting of a GE Jenbacher JGS 316 cogeneration unit, comprises a reciprocating engine (Otto cycle) fuelled by natural gas and directly coupled to a three-phase synchronous electric generator. The unit, designed to dissipate the engine's radiant energy and reduce noise (55 dB at 10 m), is equipped with all the auxiliary devices necessary for operation and a containment package. In addition to the cogeneration part, the plant is able to recover the thermal energy present in the internal circuits of the engine (first stage of the intercooler, lubricating oil, liners) and that obtained from the exhaust gases in the form of:

Hot water at 90°C, used by the product drying system;

Steam at 10 barg, used by the process machines and produced by installing a heat recovery boiler fuelled by the same 90°C water from heat recovery.

Finally, the low-temperature energy from the intercooler circuit, which is around 40°C, is dissipated into the atmosphere.

The plant has been designed for very high efficiency, estimated at +85% compared to natural gas, resulting from the electrical efficiency of the engine and the complete recovery of cogenerated thermal energy, which allows it to be classified as High Efficiency Cogeneration.

It also includes the connections for the thermal utilities, identified together with the customer, a thermal power plant and three machines, with a complex distribution network several hundred metres long distributed throughout the plant.

The project has been successfully completed, with the plant currently in operation at the Effeffe Pet Food factory.

The results achieved include a significant reduction in energy costs, improved environmental sustainability and optimisation of production processes.