Global Nutrition Provider

Thermal Energy International has delivered projects for this global nutrition customer across multiple sites in 11 countries. This long-term partnership demonstrates how Thermal Energy International has the scale and technical depth to align global sustainability strategy with engineering delivery on the ground. 

Dairies icon
Industry

Dairies

placeholder_1038668
Location

Europe

settings_834938
Solution

FLU-ACE™ 

Explore Dairy Solutions
D02a Global Nutrition Provider

3,138
MWh/year

Total energy savings

581
tonnes

CO₂ savings

<
2.5

ROI (Years)

This facility uses drying processes to produce specialised infant nutrition. Drying is an energy-intensive process, with spray drying and concentration accounting for 25% of energy use in the dairy industry. Typically, 60% to 80% of this energy is available in exhaust gases, providing significant opportunities for heat recovery. The facility is now exploring the replication of this technology at additional sites globally.

The Chief Operations Officer said:

Thanks to our partnership with Thermal Energy International, and the global and local teams working together to continue to reduce the environmental impact of our supply chain

This project builds on the success of a previous pilot installation of Thermal Energy’s FLU-ACE technology at another site in Europe, where energy consumption was reduced by 12%. The same technology was then replicated at this site to recover waste heat from the spray dryer burner exhaust and use it to preheat incoming air, reducing the load on existing heaters.

Heat Recovery Curve from boiler plant exhaust

As a result, the system;

  • Will recover up to 600 kW from the burner exhaust, with flue gas temperature of 230°C.
  • Indirect contact exchanger loop will produce 7 m³/hr of hot water at 81°C from 61°C. This will displace 163 kW of heating to boost 27 m³/hr of recuperation water from 60°C to 65°C.
  • FLU-ACE recovery loop will produce, on average, 7.7 m³/hr of hot water at 57°C. This will be used to preheat incoming air to the dryer to a maximum of 30°C. This will displace 323 kW of energy, which will vary throughout the year with ambient temperature.
The company said,

This unlocks the potential of the plant to reduce its energy consumption by a further 7%.” They went on to explain how the project is part of their energy efficiency and decarbonisation programme, which will enable the company to “improve energy efficiency by 30% by 2025 and reduce CO2 emissions in line with evidence-based climate goals.

The Net Zero Carbon Director remarked on the “significant energy reduction” achieved through heat recovery and praised the efforts of teams in specialised nutrition.

Explore FLU-ACE

Explore More Dairy Case Studies

Thermal Energy International understands the operational demands of dairy processing, from stringent quality standards to energy-intensive production and highly competitive global markets. Our proven technologies improve thermal efficiency while maintaining process integrity. By combining robust engineering with practical deployment, we enable dairy producers to lower operating costs, reduce emissions, and safeguard product quality.

Dairy and Nutrition Multinational

FLU-ACE™ delivered a payback of under two years, reduced CO₂ emissions by over 3,300 tonnes per year, cut natural gas use by approximately 1.73 million m³ annually, and recovered more than 2.4 MW of energy on average while improving CHP efficiency by over 10%.

Dairy Processing Company

Converted to GEM™ steam traps, delivering a six-month payback, over 2,500 MWh/year energy savings, and approximately 505 tonnes of CO₂e reduction annually.

Global Nutrition Provider

Implemented 2-Stage HeatSponge™ economisers, delivering annual savings of $87,900, reducing CO₂ emissions by 621 tonnes per year, and achieving a payback of under two years.

Global Nutrition Provider

Applied GEM™ steam traps sitewide for line drainage and process duty, delivering a one-year payback, 972,000 kWh annual gas savings, and approximately 180 tonnes of CO₂ reduction per year.

Global Nutrition Provider

FLU-ACE™ delivered up to 1 MW of recovered energy, reduced CO₂ emissions by approximately 1,500 tonnes per year, cut natural gas consumption by around 75%, and increased boiler efficiency by roughly 20%.

Global Nutrition Provider

FLU-ACE™ delivered over 15,000 tonnes of CO₂ savings to date, recovered more than 2.7 MW of energy across four systems, and eliminated electric cooling load while supporting net-zero objectives.

Major Dairy Producer

Installed FLU-ACE™ heat recovery and economisers to capture CHP exhaust energy, cutting gas use by 22%, reducing CO₂ by 1,325 tonnes, and saving 3.2 GWh annually with payback in under two years.

Global Nutrition Company

FLU-ACE™ delivered 3,138 MWh per year in energy savings, reduced CO₂ emissions by 581 tonnes annually, and achieved a return on investment of under 2.5 years.
All case studies

Speak to our team

Complete the form to speak with a thermal energy specialist about proven solutions that deliver measurable savings with minimal operational risk.

Get in touch