Manufacturing energy efficiency through waste heat recovery
Manufacturing energy efficiency begins with understanding how the plant uses and loses energy. Heated exhaust from ovens, dryers, boilers, furnaces, process ventilation, and production equipment may offer recoverable thermal energy.
Build a project around actual conditions
ThermStar screens sources against useful heating demands so teams can focus on opportunities with practical operating value.
Industrial energy efficiency projects require reliable source data, demand data, schedules, facility constraints, and utility costs. ThermStar reviews these factors before developing a preliminary configuration. The analysis can cover one source or compare several opportunities within a plant.
Recover energy from challenging exhaust
Manufacturing heat recovery systems may face dust, lint, humidity, oils, or other contaminants. Lepido® source technology is designed for conditions where dense finned or plate equipment can become difficult to maintain.
Application approval depends on the specific exhaust and current technical information.
Waste heat recovery solutions across industries
Wherever hot exhaust and a useful thermal demand exist, there may be an opportunity to recover and reuse that energy. ThermStar™ applies the same assessment process across industries to identify the strongest opportunities. From a single exhaust source to a multi-facility network, the system can be configured around the application.
Industrial Laundry
Recover heat from lint laden dryer exhaust and cut natural gas costs. Built for the conditions that make conventional laundry heat recovery fail.
Food Manufacturing
Recover energy from oven, cooking and process exhaust in food manufacturing, including humid and particulate laden streams that foul conventional units.
Pet Food Manufacturing
Extrusion, drying and rendering exhaust carries recoverable energy along with moisture and particulate. See how ThermStar handles these conditions.
Foundries
Recover useful thermal energy from furnace and process exhaust in foundry operations, in conditions where conventional recovery is hard to maintain.
Manufacturing
Turn exhausted thermal energy into lower operating costs and reduced emissions across manufacturing operations and multiple facility networks.
Restaurants & Commercial Kitchens
Grease laden kitchen exhaust carries energy worth recovering. The technology behind ThermStar was developed for exactly these conditions.
Industrial energy efficiency projects and sustainability goals
Sustainability solutions for manufacturers should connect environmental goals to measurable operating results. Recovering useful heat can reduce purchased energy and associated emissions when actual operation supports the calculation. ThermStar Power Intelligence can provide data for performance review and approved reporting.
A scalable platform
Sustainable industrial energy solutions can begin with one qualified project and expand as results and site conditions support further deployment. ThermStar can work with customers, utilities, original equipment manufacturers, distributors, engineering firms, and installation contractors while respecting each partner's scope and end customer relationship.
A practical decarbonization measure
Industrial decarbonization solutions do not always require replacing the underlying process. Heat recovery can improve how efficiently existing thermal energy is used. Request an Assessment to identify sources, loads, and the information needed to evaluate a first project or a facility network.
What happens next
A first conversation helps ThermStar understand the operating goal, the facility context, and the people involved in the decision.
From there, the team can identify the smallest useful information request and determine whether a screen, technical review, partner discussion, or document request is appropriate.
This approach keeps the process proportionate to the opportunity while giving operations, finance, engineering, health and safety, and sustainability stakeholders clear information for the next decision.
What makes a manufacturing heat recovery project viable
The strongest candidates have a consistent thermal source, a productive receiving load, useful temperature alignment, overlapping operating hours, workable integration, and enough displaced energy value to support the project. A high exhaust temperature by itself is not sufficient.
What can recovered process heat be used for in manufacturing
Possible uses include approved process air, makeup air, process water, domestic hot water, boiler feedwater, and other thermal demands. The selected use must be compatible with the available temperature, capacity, schedule, location, controls, and facility requirements.
Can several manufacturing sites be evaluated together
Yes. An organization can begin with a portfolio screen using consistent information from multiple sites. ThermStar can help identify which locations deserve deeper review. Findings from one project may inform later work, but each facility still requires confirmation.
How are manufacturing energy savings confirmed
Savings are based on useful recovered energy and the energy it displaces. A project specific method may use temperature, fluid flow, operating time, equipment status, baseline efficiency, and approved conversion factors. Actual reporting depends on the installed monitoring and any utility or internal requirements.