1. The Khorolska Mechanised Bak-
ery Private Enterprise undertakes
for production of bread, bakery
products, crackers, biscuits and
long-storage pastries.
The bakery started operation
more than 70 year ago. At that time,
it only had one oven and the dough
hadtobekneadedbyhand.Todayit
is a modern enterprise with its own
accreditedlaboratorytocontrolraw
inputs and finished products, and
a food safety management system.
Everydaythebakerybakesandsup-
plies its products to 11 districts of
Poltava Oblast.
The technological produc-
tion process involves a number of
successivestepsfromreceivingand
storing flour to packing finished
products. The flour is transported
to, and bolted at the production
shopwherebakeryproductsarebe-
ingmade.Theprocessinvolvespro-
portioning necessary components,
preparation of semi-finished prod-
ucts,doughkneading,proofing,cut-
tingandsteamingthedoughpieces.
The last step involves baking, cut-
ting and packing the produce.
To provide for its technolog-
ical needs, the enterprise uses en-
ergy resources: natural gas, wood
and electricity.
About the Company
operates gas-fired ovens. The pro-
duction technology involves con-
sumption of significant amounts of
energy, the cost of which affects
the price for products. Hence, en-
ergy saving is undoubtedly of rele-
vance for the enterprise. In order to
design and implement respective
measures, the Khorolska Bakery
took part in the Advisory Services
for Energy Efficiency in Companies
Project implemented in Ukraine
by Deutsche Gesellschaft für In-
ternationale Zusammenarbeit
(GIZ) GmbH commissioned by the
German Government in political
partnership with the Ministry of
Economy of Ukraine.
In autumn of 2018 the team
of national and international
certified energy auditors held
energy efficiency audit of the
For decades, the bakery has been
continuously improving its techno-
logical processes. In early days the
oven was fired with reed sourced
by its own employees from marsh-
es around nearby villages. In five
years, the production grew so ov-
ens were converted to coal. Later
on, the production increased even
more bringing respective techno-
logical changes. Today the bakery
Path to Success
Establishment date
Location
Industry
No. shops
No. working shifts
Working shift duration
Staff
Output
1948
Khorol,
Poltava Oblast
Bakery
1
2
12
93
2 764
hours
tons/year
Electricity
Natural gas
Wood
Total emissions
373
234
99
935
313
242
80
866
MWh/year
m3
t
tCO2eq
/year
2018 2019
Indicators
Review
Pilot Projects
on Energy Modernisation
in Industry
Khorolska Mechanised
Bakery, PE
МІНІСТЕРСТВО ЕКОНОМІКИ УКРАЇНИ
CO
M
PA
N
Y
2. Based on the energy audit find-
ings, the enterprise began to im-
plement the recommended energy
efficiency measures primarily for its
oven equipment, which is the most
Energy Efficiency
Measures
enterprise according to the stand-
ard ISO 50002, type 2. The audit
resulted in a range of respective
recommendations and measures.
Some of the were successfully
implemented by the enterprise
in 2019.
Besides the energy audit, a
training was also carried out to
Efficiency Bakers’ Network es-
tablished with support from the
Advisory Services for Energy Ef-
ficiency in Companies Project.
The network unites a total of 13
companies from the baking in-
dustry who exchange experience
and receive support on energy ef-
ficiency measure implementation
provide employees with knowl-
edge on energy-saving topics
of relevance for the enterprise.
This allowed a chance of bringing
their attention to potential bene-
fits of energy efficiency measure
implementation.
In March of 2019 the Khorol-
ska Bakery joined the Energy
from some lead consultants. The
membership in the network al-
lows the Khorolska Bakery and
other network participants reduc-
ing their energy consumption and
cutting on GHG emissions as well
as helps them better comply with
modern standards and become
more competitive.
energy-intensive consumer in the
bakery. Instrument-based adjustment
of burners and thermal insulation of
the oven shells allowed a significant
reduction of gas consumption.
Thermal Insulation of Oven
Shell
Photo:
The oven is known to be the key
equipmentinbreadbaking;itisalso
knownforconsuminglotsofenergy.
The Khorolska bakery uses tunnel
and hearth gas ovens. The natural
gas is burned in their combustion
chambers fitted with burners. The
closed design of the combustion
chamber ensures efficient gas
combustion;however,overtimeun-
wantedairinflowshappenthatlead
to deterioration of gas combustion
quality and result in its increased
consumption. One of the reasons
behindsuchover-consumptionisin-
efficiency of burner unit operation.
This is an unwanted consequence
fortheenterprisethatmateriallyin-
creases energy consumption costs.
To verify the efficiency of fuel
combustion, the ratio of the gas
and the air fed into the chamber
has to be calculated. This ratio is
expressed as the excess air factor,
α. The factor value of more than
1.15 tells of excess air presence
and more gas needed to heat it. In
thiscase,adjustmentstotheburner
unit are due.
Before the measure imple-
mentation the α factor value was
intherangebetween2.72and1.87.
Based on energy audit results, the
en-terprise used its own resources
to carry out adjustments of two
burners of the tunnel ovens. The
exhaust gas analyser was used to
measure fuel combustion quality. It
resultedinfactorαrestorationback
to its statutory value of 1.12.
Thanks to the adjustment of
the burners the enterprise was able
to reduce natural gas consumption
by 7% and save UAH 96 thousand a
year. The measure was implement-
ed in an incredibly short time - just
twodays–andatlowcostasnoex-
ternal contractors were needed. In
theseconditionsthepaybackperiod
was a little more than one month.
Duration of implementation
Implementation period
Implementation costs
Natural gas consumption
before implementation
after implementation
Natural gas consumption reduction
Savings from implementation
Simple payback period
Emission reduction
2 days
09.2019
10 000
161,89
149,89
12
96 000
1 month
23
UAH
thousand m3
/year
thousand m3
/year
thousand m3
/year
UAH/year
tCO2eq
/year
Indicators
Adjustment of Oven Burners
3. Thermal Insulation of Oven Shell
An inspection and thermal imag-
ing of the ovens revealed burn-
outs in the lining and poor shell
insulation. To reduce heat loss-
es, a total of 72 m2
of the oven
shell was insulated. For this
the insulation material with the
following specifications: thick-
ness: 10 cm; thermal conduc-
tivity: 0.037 W/ (m·К); density:
135 kg/ m3
; working temperature:
up to 780 °С was used.
The enterprise was also able
to implement the measure on its
own and in a short time (within
one month). The cost of purchased
materials paid off in six months.
Following the implementation,
the natural gas consumption for
oven operation was reduced by
about 9% bringing cost savings of
UAH 115.2 thousand/year. Better
labour safety became another
important advantage: insulation
of high-temp areas reduced risks
of work accidents.
Duration of procurement procedure
Duration of implementation
Implementation period
Implementation costs
Natural gas consumption
before implementation
after implementation
Natural gas consumption reduction
Implementation savings
Simple payback period
Emission reduction
5 days
1 month
10.2019
60 000
149,89
135,49
14,4
115 200
6 months
27
UAH
m3
/year
m3
/year
m3
/year
UAH/year
tCO2eq
/year
Indicators
Adjustment of Oven Burners
Photo:
