Industry first - New three-step heat recovery system trialled at NSW processing plant

A novel three-step heat recovery system that uses heat discharged from refrigeration to offset grid gas will be demonstrated through a new project funded by the Australian Meat Processor Corporation (AMPC).

Australian red meat processors are currently facing growing challenges due to increasing gas prices and cost of supply. For many plants across the country, natural gas remains the primary source of thermal energy, accounting for 54 per cent of process heat across the industry.

Since 2020, some small- to medium-sized processors, particularly in regional Victoria and New South Wales, have seen gas prices double. 

AMPC Program Manager Sustainability Matthew Deegan said, “Gas is widely used in red meat processing facilities for essential sanitisation. This research aims to demonstrate a feasible and affordable three-step heat recovery system that uses heat discharged from refrigeration as an alternative to gas. By doing so, processors can reduce reliance on grid gas, lower energy costs, and ultimately cut emissions.” 

“Early modelling indicates the system could offset up to 95 per cent of grid gas use in a medium-sized non-rendering facility, delivering around $600,000 in annual gas cost savings with a potential payback period of less than four years.

“This 12-month project has recently commenced at a regional New South Wales processing plant and will produce a case study to support industry adoption.”

Stage one of this research will focus on developing a new heat recovery system for low-grade heat using a two-step, closed-loop, temperature lift from 15°C to 55°C. It is designed for cost-effectiveness, quick implementation, more efficient performance, and later-stage integration with a third active heat recovery step.

The next stage proposes to build on the work completed by adding a third temperature lift to raise the temperature from 55°C to 88°C. This will be achieved through the integration of a heat pump to help meet the sanitisation requirements of 82.5°C. 

Outcomes from stage one of the research will be available in 2026. 

If you would like information or to get involved with similar projects, contact AMPC Program Manager Matthew Deegan at m.deegan@ampc.com.au