As a leading manufacturer of potato processing equipment, Heat and Control acknowledges the critical importance of sustainability in today’s world. Beyond industry-leading solutions, we’re also committed to helping processors in the MEASA region reduce their carbon footprint, while enhancing productivity through the transition of renewable energy.
SUSTAINABILITY CHALLENGE: ENERGY RECOVERY
APPLICATION: FRENCH FRY
Within the broader landscape of potato processing, each product type presents unique challenges that affect sustainability goals. In the context of French Fry production — significant energy is consumed throughout the blanching, drying, and frying processes.
Ideally, much of this energy could be recovered and recycled. As drying and blanching typically take place at lower temperatures (compared to frying), it’s fairly common to utilise waste heat from the fryer stack to provide some of the energy needed by the dryers and blanchers. That said — a significant amount of steam heating is still necessary, which can be costly and contributes to your carbon footprint.
To meet this challenge, our engineers developed an innovative strategy to allow potato processers to power all of their blanching and drying processes with waste heat. The system works by adding a small amount of extra (renewable) energy to the fryer exhaust, which enables the capture and recovery of a much larger portion of the waste heat. This cutting-edge innovation provides a saving of up to 40% of the total heating requirement of the French Fry line — while also delivering an impressive 50% reduction in greenhouse gas emissions! This impressive outcome is a result of the utilisation of thermodynamic engineering and process expertise.
SUSTAINABILITY CHALLENGE: ENERGY EFFICIENCY
APPLICATION: BATCH FRYING
Driven by robust consumer demand for ‘hard-bite’, ‘natural’, and ‘Kettle-style’ potato chips, batch fryers remain as a favored choice among potato processors. However, a key sustainability challenge is found in the efficiency of traditional pan-fired batch fryers, which tend to consume more fuel per kilogram of product, compared to modern continuous frying systems.
We’ve developed and manufactured three advanced systems — which allow batch frying to approach the same level of energy efficiency found in the best continuous frying systems — while still preserving the premium product qualities inherent to the batch frying process.
#1. Booster Heater for Batch Fryers (BF-BH)
Our Booster Heater for batch fryers is an exciting innovation for processers of batch fried potato chips. This equipment recovers waste heat from your fryer’s burner exhaust (chimney) and uses it to boost the heat input to the fryer. It can be applied to new builds, or retrofitted to your existing fryers in the field. Adapting or upgrading your production line with a Booster Heater will include an oil circulation system that offers additional benefits for product consistency, with an option for filtration.
BF-BH can reduce gas consumption by up to 30% which is a great saving in energy and greenhouse gas emissions.
#2. Thermal Oil Heater Batch Fryer (MTKF)
Our MTKF is a batch fryer heated by thermal oil, making it compatible with a highly efficient thermal oil heating system. Its suitability is particularly notable for sites employing multiple fryers, as a single thermal oil heater can efficiently heat several fryers simultaneously.
#3. Universal Potato Chip Fryer (UPC)
Our revolutionary Universal Potato Chip fryer (UPC) is a continuous frying system that has the ability to replicate batch fried product — with a higher production capacity, great consistency and high energy efficiency.
SUSTAINABILITY CHALLENGE: WATER CONSERVATION
APPLICATION: POTATO CHIP FRYERS
Production of potato chips comes with its own set of sustainability challenges, particularly in regions where resources are scarce. A key challenge is the significant amount of water required for washing and preparing potatoes prior to frying. While water conservation is a global priority, its importance is even more pronounced in the Middle East, where water scarcity is a critical concern.
At Heat and Control, we’re committed to enhancing the efficiency and productivity of your operation. Our latest innovations in water conservation provide a significant breakthrough in sustainability, helping you optimise water usage without compromising on quality or performance.
SWSM is a water clean-up module that removes up to 90% of the starch from a potato slice washer and allows the processor to dramatically reduce water consumption. The cleaned-up water can be re-used directly in other processes (eg peeling and whole potato washing) without expensive external water treatment plants. Our PRSM is another water module that can remove larger particles from peeler and washer systems and minimise the amount of external water turnover required.
Earlier versions of SWSM have become standard equipment for many of the leading potato chip brands. And, with the introduction of our latest generation of SWSM, processors such as these are further enhancing their performance and sustainability outcomes.
Choosing the Right Sustainability Partner
Positive results from our sustainability solutions are gaining the attention of potato processors globally. We have fast, high-performance, and sustainable equipment solutions for every aspect of your production line, along with innovative problem-solving approaches. Visit us at Gulfood Manufacturing 2024 in Dubai from November 5 – 7 at Hall 3, Stand #D3-4, and chat with our experts about your unique processing needs.
