Food manufacturing facilities often use lots of energy.
Most will require large volumes of hot water for process, cooking & cleaning. Large volumes of chilled water are likely to be used for process and even more cooling to keep products fresh after and during manufacture.
Most hot water heating will be with gas or oil driven boilers and the cooling achieved through air cooled chillers, blast chillers/freezers and cold rooms.
Cooling equipment is likely to be electrically driven and often consumes up to 50% of all electricity used on site.
What if your cooling costs and carbon could be cut in half?
What if by generating your own electricity on site you could cut your electric costs by 20-40%?
What if your hot water heating costs and resultant carbon could be eliminated?
Manzana work with manufacturers to reduce energy costs and carbon. We offer a free of charge site audit to identify quick pay back energy efficiency measures.
All solutions can be financed, meaning zero upfront investment. We target solutions with 2-3 payback, that can be financed over 4-6 years, making it profitable from year 1. For more information please click the “Grants” tab
We have many solutions to reduce energy and running costs in food and beverage manufacturing facilities, here are some of our favorites:
Free Hot Water From Blast Chillers
Do you use blast chillers and/or cold stores?
Do you know that you could replace the refrigerant PAC, so it can recover the heat which is usually dissipated to the external air?
Our PAC systems for cold stores and blast chillers, use C02 refrigerant and produce low temperature refrigerant and hot water simultaneously. In refrigeration, the by-product of cooling is heat.
In most manufacturing facilities, the heat from the cooling process is dissipated to outside atmosphere using fans on the condenser or dry air cooler. This heat can be transferred directly to water for use in process, or as domestic hot water. If you are doing more cooling than heating, you could potentially produce all hot water this way, eliminating the need to run gas or oil fired boilers. Heat recovery PAC’s cost the same to run as a conventional pack, but produce hot water a by-product.
These solutions can all be financed with zero upfront cost
Free Hot Water From Chiller Plant
Do you have a requirement for both chilled and hot water for domestic hot water/comfort cooling or/and for manufacturing process purposes?
What if we could completely eradicate your heating cost?
How much would you save?
Our dual energy heat pumps produce hot and chilled water simultaneously. In refrigeration, the by product of cooling is heat. In most manufacturing facilities, the heat from the cooling process is dissipated to outside atmosphere using fans on the condenser or via a dry air cooler. Dual energy heat pumps use C02 or R513a (HFO) refrigerant. The C02 variant is perfect for applications where you need large volumes of hot water up to 90 degrees and also have a cooling load. The dual fuel heat pump is installed on the return to the exiting chiller plant. By doing so, it acts as the lead chiller and while there is cooling load, produces free hot water for use in process or for domestic hot water purposes.
Free Electricity Generated From Waste Heat
,Do you have waste heat from your manufacturing process?
Did you know that it can be captured and used to generate free electricity?
Organic Rankine Cycle (ORC) technology is used to generate low cost electricity.
In simple terms, ORC units use hot water to drive a turbine, which in turn generates electricity.
If you have waste heat from your process, this can be captured using heat exchangers, transferred to water and then fed to an ORC unit, generating electricity from what would have been wasted energy.
Until recently, the manufacturers in this industry only provided large scale systems, for big energy producers. Recently, smaller units have been released to the market so that manufacturers can use waste heat to produce their own, low carbon, low cost electricity.
Generate Cooling During Off-Peak Times, Store & Use It When You need it
Cold Batteries are a product which can be used to store cooling energy.
Cold batteries are made from various materials which are highly efficient in storing cooling. Storing cooling in cold batteries in comparison to storing in water, reduces volume by 2/3’s and so large amounts of energy can be stored in a relatively small space.
Why store cooling?
- Chillers can be run at time that cheap (off-peak) electricity is available
- Additional cooling can be stored for peak cooling requirements if plant is not big enough
- By product cooling energy can be stored for when it is needed
- Night-time noise restrictions can prohibit chillers being run, storage makes cooling available at these times
Low Carbon, Low Cost Electricity
Do you use lots of electricity on site?
Do you also have a constant demand for either chilled or hot water?
What if you could produce low cost electricity onsite and as a bi-product produce chilled or hot water?
Combined Heat and Power (CHP) converts gas into both electricity and heat. CHP maximises the fuel and converts it into electricity at around 35% efficiency and heat at around 50%. Heat is recovered from the engine by removal from the exhaust, water jacket and oil cooling circuits.
Typically a good CHP scheme can deliver an efficiency increase of anything up to 25%compared to the separate energy systems it replaces.
The heat produced by the CHP engine, is often used for space heating or domestic hot water purposes. To make CHP work all, or the majority of the heat needs to be used. This is because the carbon free nature of the hot water produced by the CHP offsets the relatively high carbon content of the gas which is used to run the engine generator.
If there is insufficient heating load, the next consideration should be the cooling load on the site. The heat produced by the CHP engine can also be used to drive an absorption chiller (please see cooling section of this website), allowing the bi-product heat to be fully utilised to satisfy the site cooling demand.
We care about the environment
At Manzana, we care about the world we live in. We know how much difference the implementation of a building service energy strategy, can have on energy use and carbon emissions. We feel it is our responsibility to guide businesses like yours to achieve considerable energy reduction
15 years experience of low carbon technology
We have more than 20 years experience in mechanical and electrical Engineering. More than 15 years of this has been working with low carbon and renewable technology. We have had first-hand experience of thePro’s and con’s of various technologies through their life time. We have learnt what is required to provide solutions that deliver as intended.
We tailor solutions to your business
Achieving energy, carbon emissions and running cost savings in commercial and industrial settings is far from a one size fits all situation. It is important to understand exactly how much cooling, heating and electricity you use, where and when waste heat/cooling is available and at what times during the day. As part of our free consultation we identify this and then design a scheme Which takes all of this into account.