Swaegers uses waste heat to reduce natural gas consumption

Swaegers & Co NV has a modern NH₃/CO₂ refrigeration system, but identified further opportunities to optimise energy consumption in its meat processing operations. Encon investigated how residual heat from that system could be utilised to meet the site’s high hot water demand. By combining the sustainability assessment with the mandatory energy audit, Swaegers immediately received a phased investment plan to further reduce its natural gas consumption.

High hot water demand alongside modern refrigeration

As a cattle abattoir and meat processor, Swaegers has a significant demand for hot water. Cleaning, sterilisation and sanitary facilities require a constant supply of heat, whilst a modern NH₃/CO₂ refrigeration system on the same site discharges large quantities of heat. Swaegers therefore wanted to know how much of that available energy could be reused.

This investigation had to go beyond simply optimising a single system. At the same time, Swaegers had to comply with the mandatory energy audit by the end of 2026. The question was therefore not only what technical interventions were possible, but also which measures were economically viable and would fit logically into a broader investment plan.

Encon links the cooling system to heat demand

Encon carried out the VLAIO Greening Scan and the energy audit simultaneously. This meant that the strategic opportunities for further sustainability improvements were immediately linked to the site’s overall energy performance. The analysis brought together the heat demand and the available residual heat potential of the cooling system in a single industrial energy balance.

That was also where Encon’s unique approach lay. A cooling specialist primarily focuses on the cooling system, whilst a specialist in heat production mainly looks at boilers and hot water production. Encon combined expertise in cooling, heating and heat pumps and compared oil cooling, condenser recovery, a desuperheater and electrification via a heat pump. The scenarios were also coordinated with Swaegers’ in-house cooling specialist, ensuring that the proposed measures are not only energetically beneficial but also technically feasible.

Phased reduction in natural gas use through cost-effective measures

The analysis revealed that even a recently installed cooling system can still harbour significant residual heat potential. The most cost-effective measure is heat recovery from the oil cooling system, with a payback period of one year. This enables Swaegers to meet part of its existing heat demand using energy that is currently available within its own process.

Condenser recovery and a future heat pump then offer opportunities to further electrify hot water production. As a result, the role of natural gas can be gradually reduced to supplementary heating. Because Encon immediately integrated these measures into the energy audit, Swaegers now has a single coherent investment pathway that links energy efficiency, compliance and reduced dependence on natural gas.