High-temperature heat pump solution for industrial decarbonisation
Carrier delivers a unique system to transform waste heat into a high-temperature, low-carbon solution for major food manufacturer.
The Client
A global manufacturer of collagen-based products and edible casings sought to reduce carbon emissions across its operations by improving energy efficiency and recovering waste heat from its manufacturing processes. The client worked alongside a global engineering consultant to initiate the project with the aim to decarbonise a key production facility. This involved replacing conventional heating methods with an innovative, low-carbon heat recovery solution. This project formed part of a wider environmental initiative, supported by enterprise funding, to help the industrial business accelerate their transition towards lower carbon operations while maintaining production efficiency and reliability.
The Challenge
The client’s manufacturing process generated a significant volume of waste heat at relatively low temperatures, approximately 20°C. However, its production lines required high-temperature hot water at up to 110°C to support critical drying processes. The challenge was to capture this low-grade waste heat and efficiently upgrade it to the required high temperature, enabling reuse within the facility. This presented a major technical barrier. Achieving such a large temperature lift is difficult using conventional heat pump systems, particularly when operating within strict efficiency requirements tied to project funding. The system also needed to operate flexibly alongside the client’s existing combined heat and power (CHP) system, which created varying return temperatures depending on operational conditions. In addition, the client initially explored ammonia-based heat pump technology but required a more cost-effective, efficient and flexible alternative that could meet its decarbonisation goals while ensuring long-term reliability.
The solution
Carrier was selected to deliver a bespoke heat pump solution using low Global Warming Potential (GWP) HFO refrigerants. Instead of relying on a single heat pump, Carrier designed and implemented a highly specialised two-stage heat pump system capable of achieving the required temperature lift. The first-stage heat pump captured waste heat at approximately 20°C and increased it to around 50°C. This intermediate heat was then fed into a second stage comprising three high-temperature heat pumps connected in series. Each unit incrementally increased the temperature, ultimately delivering the required 110°C hot water for use in the client’s production processes. This cascading configuration represents a highly innovative engineering approach. By combining multiple high-temperature heat pumps in a sequential arrangement, Carrier overcame the physical limitations of single-stage systems and enabled efficient high-temperature heat recovery that would otherwise be difficult to achieve. The system utilised advanced HFO refrigerants, including R515B and R1233zd, ensuring low environmental impact while maintaining high performance and reliability. Carrier also conducted comprehensive factory testing in the presence of the client, demonstrating system performance under real-world operating conditions and validating efficiency targets required to secure project funding.
The Result
Carrier successfully delivered a highly innovative and cost-effective heat recovery system that enables the client to reuse waste heat and significantly reduce its carbon emissions. Managed by Carrier’s bespoke Automatic Logic Control (ALC) system, the overall system achieves a coefficient performance (COP) of >4.8 whilst exceeding minimum thresholds. As a result, the project delivered more than double the usable heat energy compared to electrical input. In addition, the solution was delivered within an accelerated timeframe, moving from order to commissioning in under 12 months, an exceptional achievement for a project of this technical complexity. Most importantly, this pioneering approach to industrial decarbonisation demonstrates how Carrier’s multi-stage heat pump configuration enables high-temperature heat recovery in applications where it was previously difficult or impractical. The solution provides a scalable blueprint for industrial manufacturers seeking to reduce emissions, improve energy efficiency and support their transition towards more sustainable operations. By reducing reliance on conventional heating systems, Carrier has helped establish a practical pathway towards net-zero manufacturing.
“There were some significant challenges on this project that forced Carrier to innovate and come up with solutions that we hadn’t considered before. I couldn’t be prouder of the team who showcased their expertise and for the client who has been a pillar of support throughout the process.”
Graham Smith, Carrier’s Applied Commercial Director
To find out more about Carrier’s low-carbon, industry-leading products and solutions, please visit: Industrial HVAC: Manufacturing, Logistics & Storage.
You can also write to us at uk.info@carrier.com or contact one of our Industry Experts.
