ENERGY EFFICIENCY


waste heat. Vapour recompression and heat exchangers can capture energy from exhaust streams and reuse it within the process, reducing overall demand. Despite the maturity of these technologies, they remain under-utilised in many confectionery facilities, often due to legacy plant constraints or fragmented ownership of utilities and production systems. Cooling systems also offer opportunities


for energy savings. Refrigeration systems – particularly those operating at multiple temperature levels – are frequently oversized or run continuously at fixed loads. The integration of variable speed drives, free cooling where ambient conditions allow, and


improved system controls can significantly reduce electricity consumption. The reuse of rejected heat from refrigeration systems for preheating or space heating can also be better utilised to create more energy efficient production lines.


A holistic solution? According to figures from GEA, heat production and subsequent chilling account for roughly 50% of the energy cost associated with food processing. Further, it says that more than 90% of a factory’s heat demand can be met through upgraded waste heat. It argues that the use of heat pumps can potentially eliminate boiler, and


reuse waste heat from a refrigeration plant to satisfy different heating requirements within the production process and its NEXUS Holistic Engineering Solution was designed to minimise energy use and carbon footprint across the food industry. By integrating processing and heating/cooling-solutions, rather than treating them separately, GEA says that plant-wide energy consumption can be reduced by up to 30%, sometimes even eliminating the need for a boiler. The solution sees the individual heating


and cooling process phases, with their respective temperature requirements and phase changes in the production process, as well as the technical and process- related parameters being examined in detail and reviewed together to find the most energy-efficient solution. Too often, says GEA, cooling is in the last


part of the equation, missing opportunities to make a real impact. Boilers and cooling systems are often oversized or the available waste heat streams are not used efficiently. Waste heat from cooling a cooked product can be repurposed by the heat pump to supply hot water for upstream cooking processes – creating a sustainable, cost-effective cycle. By involving an interdisciplinary team of sustainability, cooling and process experts early in the design phase, GEA believes it is possible to optimise the entire process line and achieve significant cost, energy and emission reductions. Beyond the core processing lines, utilities such as compressed air, water, and auxiliary steam systems can also often be good places to look for energy savings. Compressed air systems are often cited as one of the least efficient energy users in manufacturing. Leaks and inappropriate pressure settings can all waste huge amounts of energy. Undertaking a compressed air system audit typically reveals the potential for energy savings of up to 30%, by simply fixing leaks, optimising pressure and eliminating inappropriate end uses of the air.


Electrification and alternative energy With regulatory pressures increasingly targeting carbon intensity rather than absolute energy use, the source of energy has become as important as the quantity used. Electrification of thermal processes, where possible, can offer a pathway to decarbonisation, particularly when combined with the use of renewable electricity. On-site generation, including solar photovoltaic systems and combined heat and power (CHP) can further reduce exposure to energy price volatility. Hitting the sweet spot


Chocolate production is inherently energy- intensive, with tight temperature control required at every stage. However, Danny Van Petegem, Field Sales Manager for the


APRIL 2026 • KENNEDY’S CONFECTION • 67


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