Industrial Symbiosis - Potato Chips & Flakes

Year: 2025

Scope: Greenfield plant scope development focusing on Industrial Symbiotic relationship with adjacent factory.

Challenges:  The client sought opportunities to reduce energy consumption and improve sustainability within an energy-intensive manufacturing process of potato chip and flake processing by recovering waste thermal energy such as steam from the adjacent plant.

Results:  Team performed a detailed process and utility assessment to identify viable heat recovery opportunities. A new integrated heat recovery system was developed to capture waste thermal energy and redistribute it through a plant glycol network to support secondary heating demands. Utility demands based on production operations, time of the year, and available excess energy from adjacent factory were calculated and modeled. 

In addition to addressing symbiotic relationship the team completed FEL-1 budget analysis including full collaboration with equipment vendors, civil, architectural, and electrical teams to drive ROM estimate. 

Engineering scope included:

• Development of major equipment specification (20+ Packages)
• Development of high level PID's
• Development of full 3D building and process model with renders
• Site geotechnical and foundation report
• High level power distribution concepts and electrical load list
• Personnel and material flow evaluations