A Brazilian Food Group | 14ton Low-Nitrogen Condensing Steam Boiler System

Project Overview

A renowned Brazilian diversified food group, whose sauces and tinned products are exported to markets across South America and Europe, decided to carry out a comprehensive upgrade of its factory’s steam supply system to meet growing production capacity demands, reduce energy consumption per unit of output, and actively support the local government’s industrial emissions reduction and energy efficiency improvement initiatives.

Following rigorous technical evaluations and a global supplier comparison, the group ultimately selected the WNS series low-nitrogen integrated condensing steam boiler solution provided by Huanuo Boilers to establish an intelligent steam supply system comprising both main and auxiliary units. The project comprises one WNS12-1.25-Q and one WNS2-1.25-Q unit, with a total evaporation capacity of 14 tonnes per hour, fully replacing the existing ageing boiler equipment.

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Solution

In response to the factory’s significant fluctuations in peak and off-peak steam demand, as well as its high requirements for steam dryness and stability, Huano Boilers’ technical team proposed an integrated operating strategy of ‘the larger boiler ensuring primary supply, whilst the smaller boiler adjusts the load’:

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High-efficiency condensing design

The boilers feature a bottom-mounted furnace, a corrugated furnace tube and an integrated two-pass flue gas condensing structure. With a large heat transfer area and compact design, their flue gas exhaust temperature is significantly lower than that of conventional boilers, achieving a thermal efficiency of up to 99 per cent and meeting international Class 1 energy efficiency standards.

Intelligent load adaptation

Equipped with an advanced load-adaptive control system, it automatically adjusts the start/stop status and combustion ratios of the large and small boilers according to real-time steam demand on the production line, enabling efficient operation across a wide load range of 10%–100% and completely eliminating energy wastage at low loads.

Clean, low-NOx emissions

Utilising fully automated low-NOx combustion technology, NOx emissions are well below local environmental regulatory limits, assisting customers in successfully passing environmental audits and fulfilling their commitment to green manufacturing.

Rapid response & convenient operation and maintenance

The boiler achieves rapid temperature and pressure build-up, whilst the graphical user interface supports multiple languages; local operations and maintenance personnel can independently carry out daily management and maintenance after a short training period.

Core Project Advantages

Overall energy consumption of the steam system is reduced by over 18 per cent, significantly cutting production energy costs.

Intelligent coordination between the main and auxiliary boilers substantially improves pressure stability during the canning sterilisation process—where steam demand fluctuates dramatically—eliminating batch defects caused by fluctuations in steam quality.

Fully automated operation and multiple safety interlock protections enable unattended, safe operation of the equipment.

The tail-end condensate recovery system further utilises waste heat from flue gases, reducing carbon emissions by hundreds of tonnes annually and helping the client meet its ESG targets.

Client Testimonial

“Huanuo Boilers’ solution perfectly matches our highly fluctuating steam demand; in particular, the load-adaptive function has significantly improved energy efficiency. Having been in operation for half a year, the equipment has exceeded our expectations in terms of both energy savings and stability, and has become the benchmark for energy efficiency at our South American plant.”

Carlos M.

Director of Plant Operations

“Huanuo’s SZS series steam boiler has performed very stably on our continuous paper production line. The steam pressure fluctuation is minimal, fully meeting the high-quality steam requirements of the drying cylinders. After more than a year of operation, it has maintained high thermal efficiency and a low failure rate—one of the most reliable pieces of equipment on our line.”

Budi Santoso.

Equipment Manager, a major paper group in Indonesia

“Pharmaceutical processes have extremely high requirements for steam cleanliness and temperature control. Huanuo’s electric steam boiler produces clean steam with no on-site emissions and provides precise temperature control. It helped us smoothly pass several international quality system audits. It is a boiler that truly understands the needs of the pharmaceutical industry.”

María González.

Production Director, a pharmaceutical company in Mexico

“Our hotels have very high requirements for the quietness and safety of hot water supply. Huanuo’s vacuum hot water boiler operates very quietly and maintains a stable water temperature—guests hardly notice the equipment is there. Since the upgrade, hot water complaints have dropped significantly, and management has become much easier.”

Ahmed Hassan.

Head of Engineering, a hotel group in Egypt

“The stenter machines in our dyeing and finishing process are very sensitive to thermal oil temperature stability. Huanuo’s thermal oil heater heats up quickly with minimal temperature fluctuation, and the finishing effect has improved noticeably. Fuel consumption is also considerably lower than that of the original equipment. Their after-sales service responds promptly, making the cooperation very smooth.”

Mehmet Yılmaz

Production Manager, a textile dyeing and finishing company in Türkiye

“Our washing workshop requires frequent steam on/off cycles and has limited space. Huanuo’s once-through steam boiler occupies a small footprint and produces steam within 2 to 4 minutes, fully keeping up with our pace. The steam is stable and operation is simple—very suitable for our high-intensity washing conditions.”

Rafiq Islam.

Operations Supervisor, a garment washing company in Bangladesh

“Food processing has strict requirements for both steam quality and emissions. Huanuo’s condensing steam boiler has high thermal efficiency and a low exhaust gas temperature, with NOx emissions far below local standards. It helped us easily pass environmental reviews, while natural gas costs have also dropped noticeably.”

Khalid Al-Farsi

Plant Manager, a food processing plant in Saudi Arabia

“We use local agricultural and forestry residues as boiler fuel. Huanuo’s biomass steam boiler has strong fuel adaptability and runs stably, which not only reduces fuel costs but also eases solid waste disposal pressure. Emission indicators meet local environmental requirements, and the overall benefits have exceeded expectations.”

Johan van der Merwe

Energy Manager, a beverage producer in South Africa

“Chemical plants have extremely high requirements for heat source continuity. The waste heat boiler customized by Huanuo fully recovers waste heat from process tail gas and produces steam stably, significantly reducing the cost of purchased steam. Since commissioning, the equipment has operated reliably and provided real help for our energy-saving and consumption-reduction efforts.”

Rajesh Kumar

Technical Director, a chemical company in India

“Our region has long winters and extremely low temperatures, so heating equipment must withstand severe conditions. Huanuo’s hot water boiler starts quickly and supplies heat stably even in low-temperature environments. Throughout the entire heating season, there were no unplanned shutdowns, and our residential heating guarantee capability has improved markedly.”

Dmitry Ivanov

Operations Manager, a district heating company in Russia

“Our exported fruits and vegetables have very high requirements for drying color and moisture content. Huanuo’s hot air furnace provides precise temperature control and clean hot air. After drying, the fruits and vegetables retain a natural color and stable quality, fully meeting export standards. Energy consumption is also lower than that of the original equipment, giving us more reliable capacity during peak season.”

Camila Rojas

Production Head, a fruit and vegetable processor in Chile