| Problem | Solution | Benefits |
| Getting Steam at the rated Capacity and Pressure | Steam Boilers / Thermic Fluid Heaters | Boilers and Heaters of optimum capacity can help in efficient steam production Correctly designed boilers can help save production and fuel costs greatly |
| Problem | Solution | Benefits |
| Operating Pressure Is Less Than the Required Plant Pressure | Operate The Boiler Nearer to Design Pressure | Reduction in process steam demand because of more heat content |
| Non-Uniform Blowdown | Auto Blowdown System | Maintaining TDS levels along with blowdown heat recovery can lead to additional saving of 3% fuel |
| Lower Feed Water Temperature | Feed Water Management System | Directly reduces fuel consumption. |
| Lower Variation From 20% To 50% Leads to Frequent On/Off Operation of Boiler | Efficiency Monitoring System | Fuel Savings |
| Problem | Solution | Benefits |
| Syrup Preparation Unit Requires 85 Deg C, 2 Bar(G) | Pressure Reducing Station Along with PID Based Temperature Control System | Steam Savings |
| Bottle Washer Initially Requires 55 Deg C Then 75 Deg C, 2 bar(G) | PID Based Temperature Control Ramp and Dwell Type Gradient With PRS | No damage to the bottle washer Proper cleaning and steam saving achieved |
| Problem | Solution | Benefits |
| Pasteurizer Requires 90 Deg C, Steam Pressure Requires 3-4 Bar(G) | PID Based Temperature Control with Steam PRS | Proper Pasteurization rather system going in reverse re-circulation |
| Bottle Warmer Requires 40-42 Deg C ,1 Bar(G) | PID Based Temperature Control with Steam PRS | Precise control gives steam saving and improvement in process |
| Pasteuriser And Bottle Warmer Both Facing Issue of Condensate Evacuation | Pumping Trap | No need to open bypass |
| Cooling Tunnel Requires 55-60 Deg C, 2 Bar(G) | PID Based Temperature Control with Steam PRS | Precise control gives steam saving and improvement in process |
| Bottle Washer Initially Requires 55 Deg C Then 75 Deg C, 2 bar(G) | PID Based Temperature Control Ramp and Dwell Type Gradient With PRS | No damage to the bottle washer Proper cleaning and steam saving achieved |
| Problem | Solution | Benefits |
| Syrup Preparation Unit Requires 85 Deg C, 2 Bar(G) | Pressure Reducing Station Along with PID Based Temperature Control System | Increased steam savings |
| Pet Warmer Requires 40 Deg C, 2 Bar(G) | PID Based Temperature Control with Steam PRS | Precise control gives steam saving and improvement in process |
| Sleever Direct Steam Requires 85 Deg C, 1 Bar(G) | Pressure Reducing Station | Increased steam savings |
| No Provision of Automatic Air Venting | Automatic Air Vent for Steam Inlet Line to Equipment and Header | Automatic air vents eliminate barrier of heat transfer between steam to condensate |
| Problem | Solution | Benefits |
| Pasteuriser Requires 90 Deg C, Steam Pressure Required 3-4 Bar(G) | PID Based Temperature Control with Steam PRS | Proper Pasteurisation rather system going in reverse recirculation |
| Cooling Tunnel 55-60 Deg C, 2 Bar(G) | PID Based Temperature Control with Steam PRS | Precise control gives steam saving and improvement in process |
| Sleever Direct Steam Requires 85 Deg C, 1 Bar(G) | Pressure Reducing Station | Increased steam savings |
| Problem | Solution | Benefits |
| Actual Pressure Is More Than Required Pressure | Pressure Reducing Station | Increased steam savings |
| Group Trapping Observed | Pumping Trap to Kill Stalling Conditions at Time of Control Valve Closed | Increased steam savings |
| Problem | Solution | Benefits |
| Actual Pressure Is More Than Required Pressure | Pressure Reducing Station | Increased steam savingsby ~15% |
| Thermodynamic Traps/Inverted Bucket Traps Installed So Bypass Need to Be Kept Open Resulting Huge Steam Loss | Correctly Sized Pumping Trap | Increased steam savings |
| No Provision of Automatic Air Venting | Automatic Air Vent for Steam Inlet Line to Equipment and Header | Automatic air vents eliminate barrier of heat transfer between steam to condensate |
| Problem | Solution | Benefits |
| Many Plants are Not Recovering Flash Steam and Condensate | Condensate should be Recovered by Online Steam Operated Condensate Recovery System | It helps in reduction of makeup water consumption, no need to recover evaporator water where chances of contamination are much higher All indirect injection will lead to Condensate Recovery Factor of 95% |
| Problem | Solution | Benefits |
| Many Plants Have a Problem with Valves Leaking Steam | Seatless and Glandless Valves | Piston Valves are class VI valves and by using them, we can create a plant having zero steam leak Ensures minimal pressure drops, safe working environment |
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