Energy management in small and medium-sized food plants is usually based on monthly utility bills, which conceal the link between raw-material quality and energy use. This study quantifies that link for a cottonseed oil plant in Uzbekistan processing about 50.9 kt of seed per year and embeds it in a real-time monitoring and control system. Five years of monthly metering (2020–2024), product-level energy accounts and on-site measurements were used to derive product-specific electricity consumption (SEC), an oil-balance model giving SEC per tonne of oil as a function of seed oil content, and grade-specific regressions of hull oil loss on seed moisture. Pressing, roasting and extraction account for 72.7% of plant energy use, and crude oil requires 575 kWh t−1. Over the observed range of seed oil content (15–23%), pressing-shop SEC changes by 53% and plant-level SEC by 36%, with elasticities of −1.71 and −1.06 at 19% oil content. Hull oil loss is minimised at 11.4–12.5% seed moisture, and moisture normalisation offers a saving potential of 167.8 MWh yr−1. A four-layer IoT–SCADA–PLC system reduced load fluctuation in the pressing shop from ±15% to ±5%, raised the power factor from 0.72 to 0.96 and achieved a certified 7% energy saving with a 3.3-year payback. Treating feedstock properties as measured state variables makes energy monitoring actionable in oilseed processing.
Feedstock-Aware Real-Time Energy Management in Cottonseed Oil Processing: Linking Seed Oil Content and Moisture to Specific Electricity Consumption
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Abstract
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