The Challenge
Food processors are under growing pressure to cut carbon emissions while keeping energy costs under control. This facility wanted to understand whether electrifying high-temperature heating systems could deliver both sustainability and financial returns.
What We Found
Our feasibility study showed:
- 1,200 kW electric power capacity evaluated
- 95% electrical-to-thermal efficiency achievable
- More than 2,000 tonnes CO₂ reduction potential
- 3–8 year payback under seasonal tariff structures
The Engineering Approach
Using heat & mass balance modeling, hybrid system simulations, and economic analysis, we compared:
- Direct gas + electric hybrids with flue gas recovery
- Thermal oil heating systems using shell & tube exchangers
- Electric integration (500–1200 kW) with thyristor controls
The Results
- Significant natural gas reduction through hybrid integration
- Viable payback under off-peak or renewable electricity sourcing
- Added operational flexibility with minimal process disruption
Why It Matters
Electrification isn’t just a buzzword — with the right tariff strategy and system design, it can deliver real, measurable carbon and cost benefits while positioning manufacturers for a low-carbon future.
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