Breemes extracts energy from Mars

Mars Food in Olen, Belgium, produces dry rice in an energy-intensive process. Because of the Mars commitment to sustainability combined with the pressure of rising energy prices, energy is a hot item. Breemes contributes to energy savings on different fronts, from frequency inverters for more efficient electric motor operation to lighting studies for an energy-efficient and safe working environment. 
 

Mars Food, based in Olen since 1977, produces dry rice for its Ben’s Original brand. With 130 employees, the plant has an annual capacity of up to 115,000 tonnes of rice. As part of the multinational Mars Inc., which with more than 130,000 employees worldwide and more than 450 sites is still a privately held family company, Mars Olen has great ambitions, says plant manager Ruud Lazeroms. “We want to be good at what we do: providing high product quality, best-in-class performance and a safe workplace, while also keeping costs under control and focusing on sustainability.”
 

Energy and cost savings

Rice production, from cleaning to ‘parboiling’ to packaging, is an energy-intensive process. In addition to sustainability, the pressure of rising energy and raw material prices is therefore the most significant challenge for the Belgian company. “Energy is a hot item for us,” maintenance manager Geert Wanten confirms. “We want to remain competitive and therefore need to make our processes more sustainable and efficient.” Energy efficiency initiatives are therefore an important theme at Mars, which has already taken various measures. For example, electric motors are equipped with frequency inverters to have them run more efficiently, depending on the load. In addition, Mars focuses on detecting and reducing compressed air leaks, explains Wanten. “We have a high consumption of compressed air, and leaks cost a lot of money, especially at current energy prices. A simple example: a compressed air leak that is barely audible can easily cost us € 750 a year if we do nothing about it.” The materials for the frequency inverters and a device for detecting compressed air leaks were supplied by Breemes. 

“If we need Breemes, they are there, both for the short and the long term”

The bond with Breemes is close. “They are a very reliable partner,” says Peter Hermans, electrical/controls maintenance engineer. “They are challenged by us, and then they look for economic and efficient solutions. They are also very proactive; if we have questions, we don’t have to explain everything first.” Mars is committed to simplifying its supplier management towards global contracting, says Wanten. “As part of itsme, Breemes fits in well with this. Our relationship with their people is great. If there is a problem, we only need to call or send an e-mail, and they immediately think along with us, even when delivery times for components are skyrocketing. If necessary, they provide us with alternative solutions in the interim to keep the plant running.” Lazeroms: “When we need them, they are there, both for the short and the long term. Of course, we are critical in our relationship with suppliers, but we always go for the long term and reciprocity. We want to understand from each other where the complexity lies in what we do, in order to be able to help each other. On all fronts, we try to create a win-win situation by increasingly connecting our businesses, in order to be able to respond to new markets and changing environments, with a focus on reliability and cost control. We already have a long relationship in carrying out improvement projects together, and we are now doing that for lighting. Energy is especially important for us to work on, in the context of our sustainability commitment and because of the pressures due to high energy prices.”
 

Lighting studies

Saving energy on lighting has been a theme in the relationship for thirty years, as Breemes’ account manager Dirk Dierckx knows. “At Mars in Olen we have already switched from the classic ballasts to the more energy-efficient high-frequency ballasts for fluorescent lighting. In recent years, we have conducted several lighting studies for the switch to LED.” The first major study concerned the boiler room, says Wanten. “The fluorescent lamps there were difficult to reach and, in addition to energy efficiency, safety is also very important. We now have LEDs everywhere, and in such a way that there are no longer any shadows. We also no longer need to replace all fluorescent lamps and fixtures every four years. That was always a labour-intensive job. We are now also saving a lot on costs in this way.” The new LED lighting also contributes to Mars’ goal of making the workplace not only safe, but also more pleasant, Hermans adds. 

“We’ve already switched to 90% LED”

From the beginning, Breemes has been carrying out lighting projects with products by Philips, now Signify, says Dierckx. “A reliable brand with a long service life. Depending on the requirements and circumstances, these are different products. We have already done lighting studies for the interior lighting in various parts of the factory and for the exterior lighting around the factory and in the car park. Together with people from Mars, we visited the Philips/Signify Lighting Application Centre in Eindhoven. There you can see all applications live, from warehouse to office.” Wanten: “We have already switched to 90% LED. Finally, we now have to tackle the offices.”
 

For planet Earth and planet Mars 

In addition to lighting, training is an important theme in the cooperation between Mars and Breemes, Wanten adds. “This mainly concerns courses in the field of automation. Consider frequency inverters, PLC programming and machine safety. I get positive feedback from my team about that.” The current shortage of technical staff only increases the demand for training, according to Dierckx at Breemes. “We have to retrain more and more people who have no knowledge of automation.” The level of automation is also increasing, explains Hermans. “Take PLC programming, where you have to set ever more parameters these days. We also work more with smart components, such as sensors with integrated Wi-Fi. Mechanical technicians must also understand these.”

More training is becoming crucial for rejuvenation, says Wanten. “We have to pass on knowledge and competencies to young people. It’s about the future of our children, in terms of their work, but also in terms of energy and sustainability. That’s my message: focus on sustainability. We do that for planet Earth and planet Mars.”

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