Zharkent Starch and Syrup Plant is one of the leading producers of starch and deep-processed starch products in Kazakhstan and Central Asia. Founded in 2005, the plant currently employs around 300 people. The company’s production facilities enable the processing of up to 150,000 tons of corn and grain per year, producing 28 types of products. Annual output of corn syrup reaches 75,000 tons. The plant’s products are widely used in the food, confectionery, textile, and paper industries, as well as in the production of construction materials. Approximately 45% of total production is exported, and the company’s partner network includes more than 100 companies worldwide.

Key areas of activity:

• production of starch and starch-based products;
• cultivation of grain and leguminous crops, including seed production.

The production complex was designed and built with the participation of leading global experts in the starch and syrup industry. The automation level reaches 80%, ensuring precise carbohydrate composition, high product quality, and reduced production costs. Modern instrumentation allows full control of the entire production cycle — from raw material input to finished products.

Task

For a highly automated enterprise, reliable and stable energy supply, as well as efficient energy consumption, are critically important. Every additional kilowatt-hour of electricity increases production costs, while any disruption in power supply may lead to production downtime and damage to expensive equipment.  An additional challenge was the need to select a reliable supplier and equipment, as the customer had previously experienced negative operational issues with solutions from another manufacturer.

Key project objectives:

• ensuring energy independence of the enterprise;
• reducing energy consumption costs;
• creating a reliable source of electricity and heat supply for the plant.

Outcome

The optimal solution was the implementation of an on-site energy center based on two Jenbacher gas engine cogeneration units. The project required detailed technical analysis and an extended approval process. As a result, a contract was signed between Zharkent Starch and Syrup Plant and KTS Engineering for the supply of two Jenbacher cogeneration modules with an electrical output of 1,067 kW each.

Key selection factors included:

• high reliability and innovative design of Jenbacher engines;
• proven global operating experience;
• professional technical and service team of KTS Engineering.

Solution features

1. Fast commissioning and mobility. Containerized cogeneration units are supplied with a high degree of factory readiness and are installed and connected directly at the generation site. If required, the equipment can be quickly dismantled and relocated to another site.
2. High efficiency. The overall efficiency of the energy center reaches 88.6%, while natural gas utilization efficiency approaches 90%, ensuring maximum return from the consumed fuel.
3. Energy independence. The on-site energy center reduces the plant’s dependence on regional power grids and minimizes the risk of production equipment shutdowns.
4. Energy efficiency and cost savings. The cost of energy produced by the on-site mini-CHP plant is 40–50% lower than grid tariffs, significantly reducing overall production costs and protecting the business from tariff increases.