GEA NEXUS is a holistic engineering solution designed to minimise energy use and carbon footprint in food, dairy and beverage industries.
By integrating processing and heating/cooling-solutions rather than treating them separately, GEA reduces plant-wide energy consumption by up to 30 per cent sometimes even eliminating the need for a boiler.
Already proven in the beverage and dairy industries, GEA is now introducing this approach to food processing and will present it at IFFA trade fair in Frankfurt, Germany, from May 3-8, 2025.
The motivation for food processors to reduce energy usage is strong. There is a continuous demand, both from legislators and consumers, to reduce GHG (Greenhouse Gas) emissions; the industry is also intensely competitive, with manufacturers under constant pressure to reduce costs to remain competitive.
Around 60 per cent of energy consumption in a food processing plant is used for heating and cooling operations, making this the most impactful area for efficiency improvements as well as carbon footprint reduction.
At its core, GEA NEXUS takes a holistic view of the heating and cooling requirements in the production process. From the outset, the individual process phases with their respective temperature requirements and phase changes in the production process as well as the technical and process-related parameters are examined in detail and reviewed together with the food producer to find the most energy-efficient solution.
Too often, cooling is in the last part of the equation, missing key opportunities to make a real impact.
Boilers and cooling systems are often oversized or the available waste heat streams are not used efficiently.
For example, waste heat from cooling freshly prepared pasta can be repurposed by the heat pump to supply hot water for cooking pasta upstream – creating a sustainable, cost-effective cycle.
By involving an interdisciplinary team of sustainability, cooling and process experts early in the design phase, GEA can leverage its special expertise to optimise the entire process line and achieve significant cost, energy and emission reductions for the plant.
GEA offers technical sustainability consulting services (Add Better Consulting) specifically for customers with existing production lines who are looking for assistance in assessing the potential and developing technical solutions to implement their sustainability goals.
These are translated into detailed engineering designs, intelligently integrating the utility (heating and cooling) demands into the production processes.
This approach benefits both greenfield projects and retrofitted process plants. When implemented during operation, the system ensures minimal downtime and delivers a fast return on investment.
This principle was brought into focus at Wipasz, Poland’s leading poultry producer.
The company wished to make its production more energy efficient and sustainable and challenged GEA to achieve three key objectives: keeping the plant cool; recovering waste heat to reduce energy consumption; and creating adequate ventilation, especially in the slaughter area.
Around half the plant’s energy is used for cooling, all achieved by GEA ammonia-refrigeration systems.
This includes the slaughtering and cutting areas and the temperature-sensitive chilling and freezing processes.
Two heat-recovery systems with GEA heat pump as the key component now repurpose the heat from these cooling operations to provide all the facility’s hot water needs, including the heating of the offices. The boiler remains only as a back-up.
GEA’s experience has shown that integrating this approach early in the design phase of a plant, can reduce energy usage and operating costs by 30 per cent, while CO2 and NOx emissions can be cut by up to 90 per cent. CO2 emissions can even be reduced to zero if green electricity is used.
In short, GEA NEXUS accelerates the path to net-zero emissions while ensuring energy efficiency and a strong ROI.