Gundagai Meat Processors cuts gas use and costs by recycling refrigeration heat

# What happened

# Why it matters Processors rely on hot water for sterilisation, wash-down and sanitation. GMP's 2 MW hot water boiler regularly ran near or above capacity as production grew, especially in winter when incoming water was cold. That strained boiler performance and sometimes threatened production reliability. Recovering existing refrigeration heat reduces the boiler's fuel requirement, improves refrigeration efficiency by lowering condenser load, and cuts operating costs.

# Quantified results

# How the system works

# Advantages of the staged approach

• Lower upfront capital risk: use available low-grade heat first before investing in high-capacity heat pumps.
• Better overall efficiency: recoverable heat is used directly, avoiding the electrical overhead of temperature-lifting until necessary.
• Deferred capital expenditure: the project removed the immediate need for a major boiler upgrade.

# Operational and financial context Rising gas prices, ageing boiler infrastructure and refrigeration as the largest electrical load make energy management a central operational challenge for Australian processors. Hot water demand is non-negotiable for food safety, so reducing boiler load has direct production and cost benefits. By improving condenser performance, the project also reduces refrigeration energy use and operational stress.

# Next steps and scalability The project report recommends treating heat recovery as an integrated energy system rather than a single piece of equipment. GMP plans to add an industrial heat pump to raise water to about 88°C, which would push gas displacement toward 100 percent. AMPC describes the staged model as replicable for other meat processing facilities and as a pathway toward industrial electrification with lower lifecycle cost than immediate heat pump adoption.

# Practical takeaways for other processors Processors with significant refrigeration loads and ageing boilers should evaluate whether refrigeration reject heat can preheat boiler feed water. A staged approach reduces capital exposure, improves boiler reliability quickly, and creates a logical sequence to add higher-cost electrification technologies later.

# Bottom line GMP's heat recovery installation delivers measurable gas and cost savings, improves refrigeration and boiler operation, and establishes a repeatable pathway to greater electrification and emissions reduction without major short-term disruption to plant operations.