The Challenge
Food manufacturing processes generate high-temperature exhaust streams that often go unused. This facility wanted to explore how systematic heat recovery could reduce costs and carbon emissions across multiple production lines.
What We Found
Our feasibility study identified:
- 700,000 kWh annual energy savings potential
- 129 tonnes CO₂ reduction per year
- 17 design options evaluated across process and utility systems
- 4–6 year payback for the most viable solutions
The Engineering Approach
Using pinch analysis, heat and mass balance modeling, and heat exchanger network (HEN) design, we tested recovery pathways such as:
- Flue gas recovery (75–315°C)
- Air & water preheating (10–185°C)
- Thermal fluid system optimization (182–269°C)
The Results
- Thermal boiler heat recovery: £35k annual savings, 4-year payback
- Multi-line air preheating: £33k annual savings, 5-year payback
- Combustion air preheating: £15k annual savings, 5-year payback
Why It Matters
These are realistic, validated designs that balance technical feasibility, financial return, and operational flexibility—helping food processors cut both costs and carbon emissions.
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