Industrial hot water heating can be a major energy and cost outlay for meat processors. Reducing the energy usage is good for the company’s bottom line, the environment and the public. Smart processors are checking alternative technologies for heating water for central hot water, CIP, hose stations, sanitation, cooking, etc., that not only save money and energy, but also heat water to precise temperatures.
The Food Manufacturing Magazine has announced the winners of their new Smart Sourcing Award. Creekstone Farms, a processor of premium Angus beef products, has received the award for their sourcing of a direct steam injection skid used for central hot water. According to the plant manager, they are saving 700mbtu/d on energy. When the cost of energy is $4/mbtu, that equates to an impressive $2,800 per day in energy cost savings. In addition, the impact of installing the direct steam injection system lowered the overall maintenance and parts budget with a positive $12,000 savings.
Creekstone’s old system also needed seven electrical fans that were eliminated, which also helped to reduce horsepower energy consumption.
Creekstone’s commitment to a quality product led to a focus on upgrading processes and reducing natural gas and water consumption in their sanitation procedures. Hydro-Thermal was able to supply the best system for their needs.
Process conditions for the installed system are:
- A variable flow rate of 100GPM — 600GPM
- Input temperature range of 50°F —70°F
- An outlet temperature of 165°F
- Steam pressure of 120PSIG at the heater
- Two 4in EZ heaters mounted on a plug and plumb skidded system
Overall, Creekstone Farms has benefited from:
- Reduced energy costs by being able to heat water to exact temperatures
- Heating water on-demand ensures always having enough hot water and avoiding any down-time
- Energy savings means fewer costs and lower carbon emissions
- Less scheduled maintenance also aids in preventing downtime
Many companies are looking at alternative technologies as part of process improvements and sustainability (energy savings) efforts. Hydro-Thermal has an online tool to help engineers determine if direct steam injection is a good option for their plant. Use the calculator to compare energy usage between a heat exchanger and a Hydro-Thermal steam valve. It can be found at the company’s website. Hydro-Thermal also has other white papers and information available in their knowledge center.