Taming an energy-intensive industrial process

• New hot-air reticulation system uses waste heat
• Reduced energy consumption by 20 %
• Saving € 39 000 from year one

Kalizea is a semolina factory in France specialised in grinding and processing corn into food products. Its industrial process requires a lot of energy, including electricity to power dust-removal fans and heating to dry corn kernels. Until recently, the heat used was released externally and lost. The company decided in 2009 to equip its production unit located in northeastern France with a hot-air recirculation system for grain drying.

The grain and flour drying process draws in outside air using a steam battery located on the ground floor. The battery heats the air and converts it into steam, which is then chanelled into the floor area before being filtered and expelled externally. With the new system, hot air is recirculated to compensate for any lack of ventilation in the individual floors, and to preheat fresh air which continues to be drawn into the ground floor.

Key benefits

Thanks to the clever retention and recirculation system, Kalizea has been able to reduce energy consumption by around 20 % and generate financial savings of € 39 000 from the first year. The measures also reduce the equivalent of 195 tonnes of oil and 467 tonnes of CO2 each year. Other broad environmental measures planned or underway at the company include efforts to reduce water consumption, use local raw material suppliers, and eliminate additives.