Over the last 50 years, global meat production has surged, more than tripling as demand continues to rise. In 2024, meat consumption worldwide is expected to grow by more than 1%, with the most significant increases occurring in low- and middle-income countries. This trend is part of a broader pattern where, as countries become wealthier, their per capita meat consumption rises. For instance, China has seen dramatic increases in meat consumption volume over the past few decades.
In the United States alone, the meat industry is valued at around $1.3 trillion. It is a massive industry with massive energy demands. According to the Department of Energy, animal slaughtering and processing consumes around 278 trillion BTUs and has the highest emissions intensity (0.082) within the wider food and beverage industry. For context, 1 tBTU is roughly equivalent to the energy content of 7,893 barrels of crude oil or about 293,000 kilowatt-hours of electricity.
Given the high energy demands of the meat processing industry, waste heat recovery isn't just a smart way to cut costs – it's vital for boosting efficiency and reducing environmental impact.
An air-to-water (ATW) heat recovery system collects latent waste heat from processes like refrigeration units or other equipment that expel heat into the air. Instead of letting this heat dissipate, a heat exchanger captures it.
The captured heat is then transferred from the warm air into a water loop through a heat exchanger. This process raises the water's temperature, which can then be used for various purposes within the facility.
As global meat production continues to grow, the industry faces increasing pressure to operate sustainably. Waste heat recovery can help facilities optimize energy use and reduce their environmental footprint. This is critical as both consumers and regulators demand more responsible and energy-efficient food production practices.
Energy is a major operational cost. Air-to-water waste heat recovery systems can help by repurposing excess heat to preheat water, generate steam, or support other heating needs. This reduces the facility's reliance on fuel (often natural gas), which cuts energy bills, allowing resources to be redirected to other areas of the business.
Finally, waste heat recovery offers a powerful way to lower greenhouse gas emissions. By reusing excess heat, facilities can reduce their reliance on additional energy production, which directly cuts down on CO₂ and other emissions. This not only helps meet strict environmental standards but also contributes meaningfully to wider efforts to reduce the industry’s overall carbon impact.
Cooking is fundamental to meat processing, involving the application of heat to ensure that meat products are safe for consumption. This process can take many forms, all of which generate significant amounts of waste heat:
● Boiling:
Industrial kettles or vats equipped with steam jackets or gas burners are commonly used to achieve and maintain temperatures between 212°F (100°C) and 350°F (177°C). This method provides even cooking, making it ideal for processing large batches of meat like hot dogs and corned beef, where thorough cooking and moisture retention are key.
● Roasting:
Industrial roasting uses large-scale ovens, reaching up to 500°F (260°C) with gas or electric heating. This dry-heat method relies on consistent high temperatures over long periods to cook the meat evenly and develop a flavorful crust. It's crucial for products like rotisserie chickens and roast beef, where deep heat penetration and uniform doneness are key.
● Baking:
Baking is used for meat-based products like meat pies, sausages in pastry, and pork buns, typically at temperatures around 450°F (232°C). This method browns the dough or pastry while cooking the meat filling, but significant heat loss occurs through exhaust systems and oven surfaces.
Smoking flavors and preserves products like sausages, hams, and bacon in industrial smokehouses or smoking chambers. These insulated rooms, equipped with smoke generators and heating elements, operate at temperatures between 120°F and 180°F (49°C to 82°C), depending on the meat and desired smoke intensity. The smoke, produced by burning wood chips or other materials, is circulated by fans throughout the chamber.
During the process, large amounts of heat are expelled through exhaust systems to maintain proper internal temperatures. This exhaust, often close to the chamber’s operating temperature, represents a major source of waste heat. In large-scale operations, each chamber can release thousands of BTUs per hour, depending on its size and smoking intensity.
Refrigeration is the backbone of product quality and safety, playing a critical role from the moment animals are slaughtered to the final stages of packaging. Meat processing relies heavily on various types of refrigeration equipment including:
● Walk-in Coolers maintain cool temperatures (32°F to 39°F) to preserve the quality of freshly slaughtered animals and processed products before they move on to the next stage. as well as products that have finished processing. These large, insulated spaces work tirelessly to extract heat, which is then expelled through condensers.
● Blast Freezers quickly drop temperatures to as low as -40°F to lock in meat quality for long-term storage. They use powerful fans to strip heat from the meat, with this heat later released through condensers at surprisingly high temperatures.
● Glycol Chillers circulate chilled glycol through processing lines, absorbing heat directly from the meat. This captured heat is then released through heat exchangers.
Steam is indispensable within the industry, powering critical tasks like sterilization, cooking, and cleaning. Boiler plants are the workhorses behind this, generating steam at high temperatures and pressures to meet the demands of these operations. These boilers usually run on natural gas, oil, or biomass and are built to efficiently generate steam for different stages of processing.
However, not all the energy produced is fully utilized – excess steam and heat are often vented off, representing both a loss and an opportunity.
The recovered heat from these processes can be put to use in several practical applications within the meat processing facility, turning what was once waste into a valuable asset.
Recovered heat is perfect for preheating water used in cooking, cleaning, and sterilization. This not only reduces fuel consumption in boilers but also prevents equipment overload during peak production. It’s a simple yet powerful way to make operations leaner and greener.
Recovered heat is transferred to a water loop, which is then circulated through the facility’s space heating system. The preheated water is pumped through radiators or air-handling units throughout the facility.
● Storage and Packaging Areas: Even in refrigerated zones, maintaining a slightly warmer ambient temperature (without impacting the cold chain) can reduce condensation and frost buildup, which is beneficial for both product quality and equipment longevity.
● Employee Comfort: Workers in meat processing spend long hours in cold environments, like coolers and refrigerated rooms. Well-heated break rooms and offices are crucial for their comfort and well-being. Keeping these spaces warm improves working conditions and helps retain staff in a physically demanding industry.
Clean-in-place (CIP) systems maintain hygiene across various critical areas within meat packing and processing facilities. They clean and sterilize equipment, cutting machines, tanks, pipelines, and other internal surfaces that come into direct contact with meat products. This includes everything from processing lines and mixers to storage tanks and filling machines.
By integrating air-to-water waste heat recovery into CIP processes, facilities can preheat the cleaning solutions and water used for sterilizing these areas. This reduces the energy required to achieve the necessary temperatures for effective cleaning.
In the meat processing industry, energy costs can be a significant burden. But with ENERVEX’s air-to-water heat recovery systems, you can turn that excess heat into valuable savings while promoting sustainability. These systems not only help reduce your energy bills but also demonstrate your facility's commitment to environmentally responsible practices—an increasingly important factor in today’s market.
The ENERVEX RHX Roof-Top Heat Exchanger System is specifically designed for demanding environments like meat processing. This turnkey system integrates seamlessly with your existing operations, providing reliable, performance without extensive downtime for installation. By capturing and repurposing waste heat, you’ll lower your facility’s carbon footprint and increase overall operational efficiency.
Ready to make a change? Connect with ENERVEX today at (800) 255-2923 or sales@enervex.com and see how our innovative solutions can help your facility lead the way in sustainability and efficiency.