Deep Energy Savings for a Food Factory Steam System: Retrofit with Removable Insulation Jackets Saves CNY 739,000 in Annual Energy Costs

Many food processing companies have completed the first round of energy-saving upgrades for major equipment such as boilers and main steam pipelines, significantly reducing energy losses. However, many factories overlook the hidden heat loss caused by steam accessories such as shut-off valves and flanges.

A food production company in Minhang District, Shanghai, faced this typical challenge. Steam valves in the workshop had remained exposed without insulation for an extended period, causing continuous heat loss. This not only increased steam consumption, but also created high workshop temperatures, food safety concerns, and a risk of personnel burns. The company selected Spirax Sarco’s removable insulation jacket energy-saving retrofit solution, successfully addressing the final energy-saving gap in its steam system and achieving substantial long-term financial benefits.

1. Existing Project Challenges

The basic insulation work for the food factory’s steam network had already been completed. However, various steam globe valves and ball valves had not been insulated, primarily because of the stringent production requirements of the food industry:

Food Safety Risks

Traditional rigid insulation using rock wool and aluminum cladding can release insulation fibers into clean production areas if the outer protective layer is damaged, directly threatening food safety. As a result, the company was reluctant to proceed with the installation.

Significant Heat Loss

Exposed high-temperature steam valves can reach surface temperatures of up to 179°C, continuously radiating heat into the workshop and consuming steam energy. Based on calculations for a DN25 BSA globe valve operating with 3 bar g steam, the annual heat loss from a single uninsulated valve can reach CNY 880.

Increased Workshop Cooling Load

The valves continuously release heat, raising the workshop temperature. To maintain a constant temperature for food storage and processing, the company had to increase its air-conditioning and cooling investment, resulting in both higher steam consumption and increased electricity costs.

Production Safety Hazards

With high-temperature valve bodies exposed, frontline operators faced a risk of burns when inspecting or operating the valves, creating a hidden hazard to safe plant operations.

2. Spirax Sarco Customized Energy-Saving Retrofit Solution

After considering the operating conditions in the clean food processing workshop, the project ultimately selected Spirax Sarco removable flexible insulation jackets as the solution, fully addressing the shortcomings of traditional insulation.

The outer layer of the insulation jacket uses high-temperature-resistant silicone-coated fiberglass fabric. It is asbestos-free, water- and oil-resistant, clean, and non-shedding, making it well suited to the hygiene standards of food processing areas.

Key Benefits

• Clean and safe: No risk of fiber shedding or contamination of the food production line, meeting the hygiene management requirements of food factories;
• Removable and reusable: During routine valve inspection and maintenance, the Spirax Sarco insulation jacket can be quickly removed and reinstalled after servicing. It can be reused repeatedly without damaging and rebuilding the insulation each time;
• Low heat storage and reduced heat loss: Under operating conditions of 400°C, the insulation material has a thermal conductivity of only 0.06 kcal/(m·h·°C). Its excellent thermal insulation performance retains heat within the valve body and significantly reduces the surface temperature;
• Phased installation: The retrofit can be implemented by area and section, eliminating the need for a plant-wide shutdown and minimizing disruption to food production schedules.

3. Project Results and Benefits

After the retrofit was completed, the valve surface temperature, previously as high as 179°C, dropped sharply, virtually eliminating radiated heat from the valves.

Combining the benefits of steam savings with reduced workshop air-conditioning and cooling energy consumption, a complete assessment estimates that the Spirax Sarco insulation retrofit project will save the food company approximately CNY 739,000 in energy costs each year.

4. Case Study Summary

After completing the first round of energy-saving upgrades for major steam equipment, many food factories mistakenly assume that all available energy-saving potential has been exhausted. However, small accessories such as valves, steam traps, and pipe fittings are often overlooked sources of energy loss.

Spirax Sarco removable insulation jackets are an ideal solution for refined energy management in the steam systems of clean facilities such as food and pharmaceutical plants. Without compromising workshop safety or affecting routine inspection and maintenance, they deliver long-term, stable energy savings at a relatively low retrofit cost.

If your food factory also has exposed steam valves with radiated heat loss, contact us for a complimentary energy assessment solution for your Spirax Sarco steam system.