Saving Cost for Frozen Food with Delta's Energy Saving Solution

Frozen food is indispensable nowadays in our busy modern daily lives. E-commerce and frozen microwavable fresh meals at malls, supermarkets and convenience stores have also accelerated the development of the processed food industry.

Food processing requires a huge amount of freezers and refrigerators to preserve freshness, and maintain specific temperatures 24 hours a day over the entire year. The electricity cost for commercial equipment is high, allowing various possibilities for saving energy.

Delta recently introduced a smart energy saving solution for a food manufacturer in China. The client mainly processes frozen hot pot ingredients, tangyuan (glutinous rice balls) and salads. The manufacturer features an automated quick-freezing production line and high standard plants. However, there is only one general power meter and a few 2nd level power meters, making it difficult to perform a detailed analysis of the electricity bills. The electricity consumption between high and low seasons is also quite different for frozen food processing. The manufacturer usually pays more than the actual amount due to low demand charges, or pays a fine if the operating power factor doesn't meet a target. Delta's one-stop energy saving consulting service installs an energy consumption data collection system for data analysis, strategy planning and energy saving construction.

In the beginning, Delta installed its Multifunction Power Meter DPM Series to monitor the energy consumption data of the equipment in real-time and set up a complete energy management system. It transmitted the collected data to the DIAEnergie Industrial Energy Management System via the PLC and Ethernet for auto recording, and uploaded to the DIAView SCADA System for visualized analysis. The analyzed data can be further used as a basis of an energy saving strategy. After actual implementation, however, the system showed that energy consumption can be 15% different between two different workshops producing the same products at the same quantity in the same plant. It means that there is equipment in idle operation. The managers solved the issue via Delta's energy management system. Delta also helped the client implement the Vector Control Drive C2000 Series to reduce the idle run of the chillers and heaters. With the variable frequency control, the energy consumption efficiency is greatly enhanced.


Introducing its energy saving solution, Delta offered the food manufacturer the following benefits:

• Efficient energy consumption
Delta's Vector Control Drive C2000 Series drives the speed of the motors on the equipment. It prevents idle running and reduces electricity cost.

• Precise demand charge analysis for high and low seasons
The DIAEnergie Industrial Energy Management System adjusts peak hour electricity usage with detailed analysis of the peak and off-peak hours. It also analyzes high and low season demand for the manufacturer to select suitable electricity usage contracts and prevent overcharges.

• Free from fines for the power factor
The DIAEnergie Industrial Energy Management System features real-time monitoring and alarm notification functions. It schedules the operation time of the high-power equipment to elevate the power factor.

• Data visualization and systematic analysis for energy saving

With energy consumption monitoring and analysis, the system reduces consumption waste with 15% savings monthly. It saves 500,000 kWh power and $380k RMB in a year.


Delta's smart energy saving solution for food manufacturing integrates the equipment, controller and communications in the factory for a complete system. The visualized data analysis offers managers equipment operation and energy consumption information in real-time, ensures operation stability, and system safety. The analyzed data can be used as reference for an energy usage strategy that saves production costs.