SUSTAINABILITY


SUSTAINABLE AND EFFICIENT EGG PRODUCTION


Egg production can be energy-intensive, with significant power needed to run everything from brooding and hatching through to egg storage and distribution. To find ways to improve efficiency and sustainability of its egg production plant while also keeping animal wellbeing a priority, Ovus Kasulke approached commercial electric motor manufacturer WEG for a bespoke solution


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limate control is essential in egg production and, to achieve high quality products, animals need to have the best quality of life possible. At Ovus Kasulke’s Santa Catarina plant,


which produces up to 500,000 eggs every day, it is essential that the aviary fans operate effectively and reliably. The fans, however, are a key contributor of electricity usage. To power the fans, they were coupled to motors with belts and pulleys. However, to develop a


more efficient and sustainable approach, Ovus Kasulke partnered with WEG’s Energy Efficiency Business Centre.


MODULAR MOTORS The new solution proposed the use of motors from the WEG Electronic Commutated Motor (WECM) line. The WECM is an electric motor with permanent magnets, giving the motor a higher power rate in a smaller frame. The WECM also has an integrated frequency inverter in its end shield, allowing the speed of the motor to be adjusted. This means that no installation or cabling of a separate drive is needed. The WECM line was developed for air handling applications such as powering fans and adheres to performance values set out in the IE5 level of the European IEC 60034-30-2 standard. The motor’s modular design makes it easier to install, repair and maintain. Its magnet technology increases the motor’s lifespan overall, but it is also equipped with several electronic protection mechanisms, preventing overload, overheating and blockages for safer operation and reliability. This contributes to lower maintenance costs and more consistent performance. The use of belts and pulleys to connect the motors to the aviary fans was a particular


area for concern in Ovus Kasulke’s existing set up, in terms of complexity and efficiency. The WECM motor range, however, could be coupled directly to the fans due to their high torque capabilities. Due to the modularity and interchangeability of the WECM range, and the number of


mounting options, retrofitting and installation was also far more straightforward, the company explains. This reduces the overall energy consumption of the system, meaning lower running costs and improved sustainability. The WECM line includes models with both single-phase and three-phase power to meet the unique needs of a range of industries. The motors are easily interchangeable with other motors for a versatile addition to a production operation, and are also Industry 4.0 compatible, making them an ideal choice for digital transformation.


ENERGY SAVINGS This new solution maintains air flow more effectively, with lower levels of noise and vibration, as well as intuitive temperature and humidity controls. This improves the aviary environment and thus gives the best quality of life for the animals, which in turn has a positive impact on product quality and output. In fact the pilot project achieved overall energy savings of 32.2% Following its success,


the project was then expanded further to 110 WECM products overall. It is predicted that these motors will reduce Ovus Kasulke’s energy consumption by around 442 Megawatt hours per year (MWh/year) and prevent the emission of 18.8 tonnes of carbon dioxide


equivalent (tCO2e). This not only represents significant financial savings, but it is also a major step towards more sustainable and more efficient egg production. For WEG, this project highlights the performance of its WECM line in all ventilation systems, as


well as providing the customer with financial savings, quality assurance and energy efficiency. WEG


www.weg.net


www.essmag.co.uk


ENERGY & SUSTAINABILITY SOLUTIONS - Autumn 2024


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