The Challenge
Food processors often run high-temperature systems that bleed valuable energy into the atmosphere. This facility wanted to know: how much could be recovered — and at what payback?
What We Found
Our feasibility study revealed:
- 2.5M kWh annual energy savings potential
- 455 tonnes CO₂ reduction per year
- 13 design options assessed under real operational scenarios
- 2–6 year payback range for the best solutions
The Engineering Approach
Using pinch analysis, heat and mass balance modeling, and HEN (Heat Exchanger Network) design, we tested multiple recovery pathways including:
- Flue gas recovery (147–386°C)
- Air and water preheating (4–60°C)
- Thermal oil heating (154–158°C)
The Results
- CHP flue gas integration: £125k annual savings, 2-year payback
- Thermal oil preheating: £121k annual savings, 5-year payback
- Multi-line air preheating: £47k annual savings, 5-year payback
Why It Matters
These solutions aren’t just technical possibilities — they’re validated, financially viable designs that cut costs and carbon while ensuring operational flexibility.
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