As a prominent manufacturer in the field of potato processing equipment, Heat and Control firmly recognizes the paramount significance of sustainability in the contemporary world. Our dedication extends beyond merely providing industry-leading solutions; we are committed to assisting processors in the MEASA region in reducing their carbon footprint while simultaneously enhancing productivity through the seamless transition to renewable energy.

Revolutionizing Potato Processing with Sustainable Innovations

Sustainability Challenge: Energy Recovery

Within the extensive realm of potato processing, each product type presents distinct challenges that impact sustainability goals. Take French Fry production, for instance. A substantial amount of energy is consumed during the blanching, drying, and frying processes. Ideally, a significant portion of this energy could be recovered and recycled. Since drying and blanching typically occur at lower temperatures compared to frying, it is quite common to utilize the waste heat from the fryer stack to provide some of the energy needed by the dryers and blanchers. However, a considerable amount of steam heating is still required, which not only incurs costs but also contributes to the carbon footprint. To address this challenge, our engineers devised an innovative strategy. This system works by adding a small amount of additional (renewable) energy to the fryer exhaust, enabling the capture and recovery of a much larger portion of the waste heat. As a result, this cutting-edge innovation leads to a savings of up to 40 percent in the total heating requirement of the French Fry line while achieving an impressive 50 percent reduction in greenhouse gas emissions. This remarkable outcome is a direct consequence of the utilization of thermodynamic engineering and process expertise.

Our continuous efforts in this area showcase our commitment to sustainable practices and our ability to make a significant impact on the environment and the bottom line.

Sustainability Challenge: Energy Efficiency

Driven by the strong consumer demand for 'hard-bite', 'natural', and 'Kettle-style' potato chips, batch fryers remain a favored choice among potato processors. Nevertheless, a key sustainability challenge lies 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. However, we have developed and manufactured three advanced systems that enable batch frying to approach the same level of energy efficiency as the best continuous frying systems while still preserving the premium product qualities inherent to the batch frying process.

Our Booster Heater for Batch Fryers (BF-BH) is an exciting innovation for batch fried potato chip processors. This equipment recovers waste heat from the fryer's burner exhaust (chimney) and uses it to boost the heat input to the fryer. It can be seamlessly integrated into new builds or retrofitted to existing fryers in the field. Adapting or upgrading your production line with a Booster Heater includes an oil circulation system that offers additional benefits for product consistency, with the option for filtration. By implementing this system, gas consumption can be reduced by up to 30 percent, resulting in significant savings in energy and greenhouse gas emissions.

The Thermal Oil Heater Batch Fryer (MTKF) is another remarkable innovation. It is a batch fryer heated by thermal oil, making it compatible with a highly efficient thermal oil heating system. This system is particularly suitable for sites with multiple fryers, as a single thermal oil heater can efficiently heat several fryers simultaneously, enhancing overall operational efficiency.

Sustainability Challenge: Water Conservation

The production of potato chips comes with its own set of sustainability challenges, especially in regions where resources are scarce. A crucial challenge is the substantial amount of water required for washing and preparing potatoes prior to frying. While water conservation is a global priority, its significance is even more pronounced in the Middle East, where water scarcity is a critical concern. At Heat and Control, we are dedicated to enhancing the efficiency and productivity of your operations. Our latest innovations in water conservation represent a significant breakthrough in sustainability, helping you optimize water usage without sacrificing quality or performance.

Our SWSM water clean-up module removes up to 90% of the starch from a potato slice washer, allowing processors to dramatically reduce water consumption. The cleaned-up water can be directly reused in other processes, such as peeling and whole potato washing, without the need for expensive external water treatment plants. Our PRSM is another water module that can remove larger particles from peeler and washer systems, minimizing the amount of external water turnover required. Earlier versions of SWSM have become standard equipment for many leading potato chip brands, and with the introduction of our latest generation of SWSM, processors are further enhancing their performance and sustainability outcomes.

Choosing the Right Sustainability Partner

The positive results achieved through our sustainability solutions are attracting the attention of potato processors worldwide. We offer fast, high-performance, and sustainable equipment solutions for every aspect of your production line, along with innovative problem-solving approaches. By partnering with us, you can embark on a journey towards sustainable potato processing and achieve remarkable results.

To learn more about Heat and Control and our comprehensive range of sustainable solutions, click here.