Leading Coffee Manufacturer Reduces Steam Losses with GEM™ Steam Traps

HeatSponge™ economizers extend boiler efficiency, cutting natural gas use by >16,600 MMBtu and CO₂e emissions by >900 tonnes a year.

FLU-ACE™ and HeatSponge™ reduced natural gas use by approximately 16%, cut CO₂e emissions by around 2,450 tonnes per year, and achieved payback in under three years.

HeatSponge™ economizers delivered $87,900 in annual savings, reduced CO₂ emissions by 621 tonnes per year, and achieved a payback of under two years.

GEM™ Steam Traps and FLU-ACE™ reduced annual steam consumption by approximately 3,400 tonnes, cut natural gas use by 20%, and have operated reliably for over a decade.

GEM™ steam traps delivered a six-month payback, over 8,500 MMBtu/year in energy savings, and reduced CO₂e emissions by approximately 505 tonnes annually.

GEM™ steam traps were deployed sitewide for line drainage and process duty, delivering a one-year payback, approximately 3,300 MMBtu/year in gas savings, and approximately 180 tonnes of CO₂ reduction per year.

PERCO-ACE™ and FLU-ACE™ delivered over 112,259 MMBtu of annual energy recovery, reduced CO₂ emissions by more than 6,100 tonnes per year, achieved payback in under one year, and enabled full decommissioning of aging boilers.

GEM™ Steam Traps reduced measured live-steam loss by almost 65%, cut annual CO₂ emissions by 277 tonnes, and achieved payback in under 10 months before funding.

GEM™ steam trap retrofit improved efficiency by 16%, delivered $20K in annual savings, achieved a payback of under two years, and reduced CO₂ emissions by approximately 100 tonnes per year.

FLU-ACE™ recovered energy from thermal oxidizer exhaust to offset natural gas consumption, delivering substantial annual fuel savings and achieving payback in under two years.

GEM™ steam traps delivered measurable efficiency gains, achieving a 19.5% intensity-based steam reduction and a 14.8% absolute reduction in steam use following retrofit.

GEM™ steam traps delivered a rapid six-month payback, eliminated mechanical trap replacement costs, and improved reliability with a 10-year no-fail guarantee.

FLU-ACE™ and HeatSponge™ heat recovery systems deliver approximately 2.1 million gallons of annual water savings, reduce CO₂ emissions by over 1,800 tonnes per year, and achieve payback in under four years.

GEM™ steam traps delivered a verified 15% reduction in steam consumption, eliminated recurring mechanical trap failures in a 24/7 process, and provided long-term reliability with a 10-year guarantee.

GEM™ steam traps ensured reliable 24-hour operation by eliminating steam losses from failed mechanical traps, reducing maintenance demands, and delivering over 10 years of dependable, maintenance-free performance.

FLU-ACE™ heat recovery and economizers captured CHP exhaust energy, reducing gas consumption by 22%, cutting CO₂ emissions by approximately 1,325 tonnes per year, and recovering around 10,900 MMBtu annually, with payback in under two years.

FLU-ACE™ delivered approximately 10,700 MMBtu/year in energy savings, reduced CO₂ emissions by 581 tonnes annually, and achieved a return on investment of under 2.5 years.

FLU-ACE™ delivered over 15,000 tonnes of CO₂ savings to date, recovered more than 9.2 MMBtu/hr of energy across four systems, and eliminated electric cooling load while supporting net-zero objectives.

FLU-ACE™ delivered up to 3.4 MMBtu/hr 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%.

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 61.2 million ft³ annually, and recovered more than 8.2 MMBtu/hr of energy on average while improving CHP efficiency by over 10%.

Hybrid FLU-ACE™ offset 71% of the LPG previously required for hot water production and reduced CO₂ emissions by 330 tonnes per year.

FLU-ACE™ reduced fuel use by 30%, cut carbon emissions by approximately 550 tonnes per year, and achieved up to 90% reductions in particulate matter and acid gases.

GEM™ steam traps reduced gas consumption per tonne of product by approximately 15%, eliminated steam losses, and delivered long-term reliability across a flagship meat processing site operating under highly variable loads.

HeatSponge™ delivered 15,242 MMBtu/year in fuel savings, approximately $83K in cost reduction, and accelerated payback through $135K in rebates.

FLU-ACE™ heat recovery reduced natural gas use by over 12% and cut CO₂ emissions by more than 480 tonnes annually while supporting process water heating.

FLU-ACE™ heat recovery reduced gas consumption by 10% and cut greenhouse gas emissions by over 2,000 tonnes per year.

FLU-ACE™ has operated for almost 10 years, cutting CO₂ emissions by more than 1,800 tonnes annually, recovering approximately 1.5 MMBtu/hr of boiler exhaust heat.

FLU-ACE™ heat recovery reduced boiler fuel consumption by 15%, improved efficiency to 96%, and cut emissions by over 7,300 tonnes per year.

FLU-ACE™ recovers ~2.5 MMBtu/hr of heat from boiler exhaust, helping this historic brewery reduce CO₂ emissions by more than 2,500 tonnes a year.

GEM™ traps replaced failing mechanical traps across key steam services, reducing steam loss and maintenance downtime.