A major UK meat processing facility has taken a huge step towards sustainable production by installing a CO₂ Twin Energy Chiller-Hot Water Generator system from Pure Thermal. This state-of-the-art installation delivers low-temperature process cooling at -12°C alongside 65°C high-grade hot water—achieving both energy efficiency and significant cost reductions.
Meeting Production Demands with One Integrated System
At the heart of this project is a Pure Twin Energy CO₂ system designed to serve a new beef ageing facility. Each chiller unit delivers 55kW of cooling power and simultaneously recovers 80kW of high-temperature heat. This dual output makes the system ideal for sites requiring both chilled glycol and continuous hot water, as is the case in this meat processing plant where hot water and steam demand remains consistent throughout the year.
With a 2,000-litre chilled water buffer tank and a 4,000-litre hot water thermal store integrated into the system, the recovered heat can be immediately reused on-site. This not only reduces energy use but also cuts reliance on fossil-fuelled heating systems.
Designed for Quality and Control
The new facility includes an advanced dry-ageing process where temperature, humidity, and airflow control are critical to delivering premium beef. The chiller system plays a key role here, supporting precise air treatment to ensure consistent product quality.
An automated control and handling system monitors conditions throughout the ageing process. In response, the cooling and humidity control technology had to match this level of precision and performance. The CO₂ Twin Energy system met the specification on all counts—delivering high-efficiency, low-temperature cooling and stable heat output.
Why CO₂ and Why Now?
CO₂ may be a natural refrigerant with roots in 19th-century cooling systems, but it is also central to the future of energy-efficient refrigeration. The environmental credentials of CO₂ are strong: it’s non-toxic, non-flammable, and carries zero ozone depletion potential.
With tightening F-gas regulations and the rising cost of synthetic refrigerants, choosing CO₂ offers long-term peace of mind. There are no phase-out risks and no associated compliance headaches—making it a sensible investment for businesses looking to future-proof their operations.
As Garry Broadbent of Pure Thermal explains:
“The client wanted a solution that matched their production demands while giving them security from both an energy and maintenance perspective. By recovering and reusing waste heat, the site now benefits from both cooling and heating without the penalties that come with conventional systems.”
Performance and Efficiency in Numbers
The efficiency of the Twin Energy system is a key differentiator. Traditional F-Gas chillers typically recover only 10% to 15% of cooling energy as usable heat. In contrast, Pure Thermal’s CO₂ system recovers between 125% and 150% of the cooling output in the form of high-grade heat.
When operating at full load with a -12°C chilled water flow, the system delivers a Total Coefficient of Performance (TCOP) over 4—equating to 400% efficiency. On projects with higher cooling temperatures (e.g., 5°C flow), that figure rises dramatically, achieving TCOPs of up to 7.
This installation alone is projected to deliver:
- Annual energy savings: £30,000+
- Annual carbon reduction: 160 tonnes of CO₂
- Payback period: 3.5 years
Supporting Systems and Smart Monitoring
The plant includes a range of integrated components, from modulating pumps and dry air coolers to heat exchangers and heat/coolth meters. These are supported by a remote monitoring system, allowing the operator to track performance in real time and identify opportunities for further savings.
By designing the system to heat incoming mains water, which is then fed into the existing steam and hot water network, the plant reduces peak boiler demand and improves overall site efficiency.
Twin Energy: Scalable and Adaptable
Although this installation focuses on food production, Twin Energy systems are well suited to a wide range of applications, including
- Hospitals and healthcare
- Hotels and hospitality
- Pharmaceutical and chemical production
- HVAC and cold storage
- Blast chilling and hot water supply
Wherever simultaneous cooling and heating are required, the Twin Energy approach provides a practical and sustainable solution.
Looking Ahead
This project reflects a broader shift in the industry. Businesses across the UK are beginning to understand the value of integrated cooling and heating systems that reduce both energy bills and carbon emissions. CO₂ technology is no longer a niche alternative—it’s fast becoming the default for new builds and retrofits alike.
By harnessing the energy already available within their processes, this leading meat processor has taken a smart and strategic step forward. As Garry Broadbent concludes:
“This project shows how CO₂ Twin Energy systems can meet demanding production requirements while delivering real commercial and environmental value. The monitoring and metering package we’ve included ensures the client can measure and verify their energy savings in real terms.”