The Challenge
Running nine production lines with ovens, fryers, dryers, and steam boilers, this snack manufacturer faced massive heat losses across their site. Rising energy costs and decarbonization pressures meant they needed a smarter way to recover waste heat.
What We Found
Through a comprehensive pinch analysis, we identified:
- 2.5 MW maximum heat recovery potential
- Up to 19.7 GWh annual energy savings
- More than 3,600 tonnes CO₂ reduction potential
- Realistic payback of 1.7–6.4 years
The Engineering Approach
Our team applied systematic thermodynamic modeling, composite curve analysis, and heat exchanger network (HEN) design across 60+ process streams. Scenarios tested included:
- Combustion air preheating
- Process water heating
- Steam system optimization
The Results
- Annual savings potential of £62,000–£598,000
- Significant Climate Change Levy and carbon tax reductions
- Modular design strategies allowing phased implementation
Why It Matters
This wasn’t a theoretical study—our methodology delivered validated, practical system designs that balance ROI, energy savings, and operational reliability.
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