Turn Waste Heat into Plant Savings

Scalding, carcass sterilisation, feather drying, hide removal, singing, and large-scale washdowns are among the heaviest thermal loads in the sector, creating sharp spikes in steam and hot water demand.

Our systems recover and store heat from these processes so it can be redeployed exactly when demand surges, reducing fuel use during peak periods. Where hygiene rules demand absolute separation between heat sources and process water, we apply closed-loop heat recovery designs to transfer energy without contamination risk.

Every plant must meet precise hygiene requirements, with water temperatures maintained to regulatory and microbiological standards. Scalding water must remain in the 60 to 71 °C (140 to 160 °F) range to prepare carcasses without causing damage. Sterilisation requires 82 to 93 °C (180 to 200 °F) to ensure compliance, while washdown water is typically kept between 49 to 71 °C (120 to 160 °F) to remove fats and residues without risking equipment damage or operator safety.

We design systems that deliver these temperatures reliably using recovered energy, reducing reliance on boilers and avoiding temperature fluctuations that could affect product quality.

Production shifts and sanitation cycles create sudden spikes in thermal demand. Boilers are often forced to operate at full output during these peaks even while large volumes of recoverable heat are vented to atmosphere.

Through hot water storage integration, recovered energy can be held and supplied exactly when required, smoothing demand peaks, improving boiler efficiency, and lowering overall fuel consumption.

Refrigeration can account for nearly a third of total site energy use, covering chilling, blast freezing, and product storage. This load runs around the clock and contributes to high site operating costs. By applying refrigeration heat reclaim, we can capture waste heat from ammonia and other systems to offset heating requirements elsewhere in the plant, cutting fuel use and reducing emissions.

When combined with heat pumps, refrigeration heat recovery can supply higher-temperature energy for space and process heating, lowering fuel use and site emissions.

Older boiler systems and oversized equipment waste fuel during part-load operation and increase the chance of unplanned downtime, which can quickly halt production and lead to product loss. Energy supply volatility and the risk of cost spikes from gas, LPG, or electricity markets add further uncertainty.

Thermal Energy International integrates improvements into live operations without disrupting production, helping plants maintain reliability, control costs, and stay on track with sustainability commitments that are increasingly linked to market access and customer relationships.