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Fågelfors Pellets – Optimization of pellet production through energy monitoring

Fågelfors Pellets faced the challenge of optimizing its pellet production and energy consumption in an industry where efficiency is key to profitability. By implementing a comprehensive energy monitoring system, the company gained deep insights into its production processes. This led to better decision-making for production planning, improved maintenance, and more accurate internal pricing. The result was a noticeably more efficient operation and increased profitability.
About Fågelfors Pellets

Fågelfors Pellets (formerly Bitus) is a company specialising in pellet production and wood processing. With facilities that include both a planing mill and a pellet factory, Fågelfors Pellets faces the challenge of optimising its production and energy use under varying conditions. 

The Challenge

In an industry where energy costs and efficient use of resources are a key determinant of profitability, Fågelfors Pellets faced several complex challenges. To remain competitive, they needed to get a better picture of their energy use and understand where in the different stages of production energy was consumed. They also needed answers to several critical questions: 

  • Is it profitable to produce pellets during the cold winter months?
  • How is energy consumption distributed between different production lines?
  • How can the production costs of different processes and products be calculated more accurately?
The Solution

To address these challenges, Fågelfors Pellets implemented energy monitoring. The system was installed to: 

  • Monitor energy consumption in real time in different production lines.
  • Measure energy consumption for heat production and drying of raw materials.
  • Collect detailed data for cost analyses.

Kristofer Lind, former site manager at Fågelfors Pellets, thinks that the co-operation has worked very well and that the system has given them valuable insights that they would not have been able to get otherwise.

Implementation and Use

Fågelfors Pellets implemented the energy monitoring system with the aim of getting an overall picture of their production. Separate monitoring systems were installed in each of the three production lines, allowing them to compare and analyse energy consumption between different processes. To understand the drying process, energy meters were installed for the heat production as well as temperature meters in the dryers. This enabled close monitoring of the drying process, which is particularly energy intensive and sensitive to external conditions.

 

 

To effectively utilise the data collected, the information is displayed in real time on screens in production. This facilitates quick identification of problems. Weekly follow-up meetings were introduced, where data is analysed to drive continuous improvements and increase staff awareness of energy use. 

Results and Insights ​

The implementation of the energy monitoring system led to several important insights and improvements: 

Optimized pellet production

The system helped Fågelfors Pellets to identify the tipping point when it becomes too expensive to dry sawdust in cold conditions. This leads to informed decisions on when to pause or resume production, resulting in more efficient and profitable operations.

Detailed cost calculation

The data collected enabled a detailed analysis of production costs for different dimensions and types of raw materials. It was realised that the planing mill was more expensive to run than previously estimated, which provided the basis for strategic decisions on the future direction of the business.

Improved maintenance

Real-time monitoring of pellet press power consumption allowed early detection of problems such as slack belts. This facilitates preventive maintenance, reducing the risk of serious breakdowns and increasing the overall uptime of the plant.

Optimized Internal pricing

Based on the thorough cost analysis, it was found that the internal pricing between sites needed to be adjusted to better reflect the real costs. The result is a fairer and more transparent internal economy within the company.

Summary

By implementing a comprehensive energy monitoring system, Fågelfors Pellets was able to get a detailed and accurate picture of its energy consumption and production costs. This led to better decision-making for production planning, maintenance and internal pricing. The system has proven to be a valuable tool for optimising operations and increasing profitability. 

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