A 365-day heat-and-cooling machine: milk reception, chilling, pasteurisation, CIP, drying, cold storage, boilers, generators and effluent — all paying for heat twice.
A large dairy runs 365 days a year and pays twice on nearly every process — once to heat the product, then again to cool it. Milk handling, chilling, pasteurisation, hot water, CIP, evaporation, drying, refrigeration, cold rooms, boilers, generators and effluent systems create exactly the thermal profile where SRU + RPC + TESS deliver value.
| Planning basis | Reference value | What it implies |
|---|---|---|
| Milk handling capacity | 3.0–3.5 million litres/day | High continuous cooling load; milk reception creates shock loads. |
| Steam demand | 20–25 TPH — roughly 360–450 MWh(th)/day depending on steam conditions and schedule | Major boiler fuel and stack-loss opportunity; a strong candidate for SRU + TESS. |
| Refrigeration | ~1,500 TR — roughly 24–36 MWh(e)/day of compressor power | TESS can buffer refrigeration peaks and cold-storage swings. |
| Current waste streams | Boiler stack losses, condensate losses, refrigeration condenser heat, cooling-tower rejection, pasteurisation heat/cool cycling, CIP and dryer exhaust | More than half of purchased energy may be rejected as waste heat or unmanaged cooling demand when thermal streams are not integrated. |
| Waste area | How the waste happens today | Technology response |
|---|---|---|
| Boiler & steam | Stack losses, blowdown, condensate losses, cycling, steam traps, unbalanced hot-water loads. | SRU + TESS recover and buffer heat; RPC where solid fuel or particulate exhaust applies. |
| Pasteurisation | Product is heated then immediately cooled; repeated cycling creates load swings. | TESS stabilises hot/cold demand and shifts recovered heat to CIP or preheat. |
| Refrigeration & cold storage | Compressor heat is rejected to condenser and cooling tower; peak loads drive demand charges. | TESS buffers chilled water and cold storage, and reduces compressor peaks. |
| Milk reception & chilling | Incoming milk creates shock loads at reception and during peak procurement windows. | TESS acts as a thermal shock absorber for consistent chilling and product quality. |
| Drying / milk powder | Drying exhaust and heated air streams reject large amounts of heat. | Recover heat for preheat, staged drying-air use, or behind-the-meter conversion where heat quality allows. |
Select one high-load island: boiler, CIP, pasteurisation or refrigeration. Meter the baseline for 2–4 weeks, install a bypassable pilot, verify savings for 30–90 days, then scale once the cash, quality, water and reliability benefits are proven.
Sidel Systems USA's SRU flue-gas condenser already runs on this exact thermal profile at Darigold — see the Darigold case study.
We would rather send you a data request than a brochure. This is what turns a conversation into a bankable project.
Monthly utility bills; boiler fuel and steam logs; stack temperatures; pasteurisation and CIP schedules; refrigeration compressor kW; cooling-tower makeup and blowdown; dryer heat data; product loss and spoilage; water and wastewater cost; site layout.
All claims relating to site savings, water reduction, output increase, emissions outcomes, payback, incentives and deployment economics are planning assumptions, analogues or prior-project references — unless and until they are validated for your specific facility through engineering, measurement, vendor quotation, financing documentation, legal review and final commercial agreements.