– A Systematic Transformation from High Energy Dependency to Efficient, Sustainable Production
I. The Client’s Challenge
A food additive plant’s core process relied on energy-intensive drying equipment, leading to two major challenges:
- High Energy Costs & Efficiency Bottlenecks: The drying stage’s natural gas consumption was a primary cost driver, with low thermal efficiency and significant heat loss. Supporting equipment like dehumidifiers further increased energy use and O&M complexity.
- Capital & Execution Hurdles for Transformation: The plant intended to retrofit but faced high upfront costs and lacked a systematic technical roadmap and execution capacity, fearing production disruptions.
II. Our Dual-Pronged Solution
ODC provided an integrated package of diagnosis, technical retrofit, and financial support:
- System Diagnosis & Planning (Outsourcing): We conducted a comprehensive energy audit and designed a roadmap centered on “biomass fuel substitution” coupled with a “total heat recovery system.”
- Technical Implementation (Development): We led the fuel system retrofit and innovatively integrated a waste heat recovery network.
- Financial Leasing Integration (Empowerment): Through our Asset Operations Division, we coordinated an equipment finance lease tailored to the client’s needs, converting major CAPEX into flexible OPEX.
III. Value Created
- Notable Economic Benefits: Overall plant energy costs fell by over 40%, and related O&M labor costs decreased significantly.
- Operational & Safety Upgrade: Reduced equipment complexity enhanced system stability and safety. Biomass fuel improved environmental compliance.
- Successful Light-Asset Transformation: The client completed a core system green upgrade with minimal upfront capital outlay.