The quest for energy efficiency and uninterrupted operational continuity in industrial manufacturing facilities continues to play a decisive role in the engineering investments of multinational corporations. Kerry Group, a global player in the taste and nutrition sector, has implemented a strategic project with Form Endüstri Ürünleri to modernize the process and HVAC infrastructure of its food manufacturing plant in Kocaeli Gebze Dilovası. The newly installed system combines cooling, heating, and simultaneous hot-cold water production technologies under a single framework, providing high flexibility and resource optimization for food production processes.
Multi-Purpose Process HVAC and Technical Capacity with a Single System
To meet the precise temperature control and continuous operation requirements of the food manufacturing lines at the Kerry Group Dilovası plant, 3 units of WSAN-YSC4 PL 175.4 air-cooled multifunctional heat pumps and 2 units of WSHH-LEE1 60.2 water-cooled heat pump systems were commissioned. The multifunctional heat pumps deployed within the scope of the project deliver a total capacity of 450 kW, while the integrated water-cooled heat pumps complete the system with an additional 230 kW capacity.
The engineering architecture developed by Form Endüstri Ürünleri contributes directly to optimizing energy costs, which represent one of the most critical expenditure items for manufacturing plants. The preferred Clivet air-cooled multifunctional heat pumps in the project synchronize high-capacity cooling and heating within the same infrastructure. Managing different temperature levels required by separate production lines simultaneously from a single source reduces investment and operational costs across the factory floor while creating space for simplification in mechanical system design.
R-32 Refrigerant Fluid and Waste Heat Recovery Technology
In line with sustainability and carbon emission reduction targets, the industrial system utilizes R-32 refrigerant fluid, which possesses a low global warming potential. In addition to this fluid technology that minimizes environmental impacts, the infrastructure features 2 independent cooling circuits, 4 scroll compressors, and 8 axial fans to enhance operational flexibility and operational reliability.
This staged compressor and fan configuration keeps energy consumption at a minimum by operating the system only at the required ratio rather than full capacity during partial load periods in the factory. Furthermore, against the risk of unexpected downtime, the independent circuits ensure that the system continues to operate in the event of a technical malfunction in any component, providing a critical operational guarantee that prevents interruptions on the food production lines.
One of the most significant engineering solutions maximizing the thermodynamic efficiency of the infrastructure has been the integrated waste heat recovery mechanism. Depending on the operational scenarios of the plant, the waste heat generated during processes is recovered and re-introduced into the system cycle, thereby lowering the factory's total primary energy consumption and supporting carbon reduction metrics.
"An Engineering Approach Strengthening Production Infrastructure"
Regarding the project's contributions to industrial manufacturing and energy management, the technical teams of Form Endüstri Ürünleri stated the following:
The Clivet solutions provided by Form Endüstri Ürünleri strengthen Kerry Group's production infrastructure in Turkey with high efficiency, flexible operation layout, and low energy costs, while offering a strong contribution to the concept of sustainable production in the food sector. This system, supported by Clivet technology, delivers high performance and operational continuity alongside optimized energy consumption, supporting the long-term efficiency goals of the facility.
