The implementation of renewable thermal technologies in energy-intensive industrial processes, such as pasteurization in the food industry, is key to reducing dependence on fossil fuels and optimizing energy consumption. These solutions not only improve sustainability but also increase the competitiveness of production plants by reducing operating costs and strengthening compliance with climate targets. In this article, we present the case of a beverage company that has installed a high-temperature heat pump to power its juice pasteurization process. We analyze the results obtained in terms of efficiency, economic savings, and emission reductions, with a projected return on investment in just 4 years.

Introduction

The packaged beverage sector requires continuous and reliable thermal processes to ensure food quality and safety. The analyzed plant previously operated with a pasteurization system primarily based on fossil-fuel steam, which resulted in high energy consumption and a significant carbon footprint. This Efficiency Case Study shows the results of integrating an industrial heat pump with an existing ammonia refrigeration system, harnessing waste heat to drastically reduce fossil steam use and the process’s energy consumption.

System Features – Industrial Heat Pump

• Supply temperature: >80 °C

• Heat pump capacity: 567 kWe

• Coefficient of performance (COP): >3.5 under industrial conditions

• Integration: Ammonia-based refrigeration system, also compatible with CO₂-cooled facilities

• Application: Preheating (25–60 °C) and pasteurization (62–68 °C) in a continuous process

Total treatment time: 20–30 minutes, meeting 15–25 Pasteurization Units (PU).

Sustainability and Emission Reduction Highlights

• Reduction in process energy consumption: 38%

• Fossil steam substitution: >56% replaced by renewable heat

• Direct contribution to decarbonization and compliance with food sector climate targets, aligned with Law 7/2021 + PNIEC: GHG reduction of 23%, renewable energy share of 42–74%, and efficiency of 39.5% by 2030

Economic Savings and Operational Efficiency

• Return on investment: 4 years

• Recognition with Energy Saving Certificates (CAEs), enhancing economic feasibility

• High operational efficiency thanks to the recovery of residual refrigeration heat

Energy Resilience and Additional Benefits

• Greater independence from fossil fuels, reducing vulnerability to price volatility

• Technology compatible with different industrial chiller configurations, such as NH₃ and CO₂

• Compliance with stricter food safety and quality standards

With this project, GDES strengthens its position as a benchmark in efficient, renewable thermal solutions adapted to the highest standards of the food industry.