Economizer Installed for Heat Recovery and More Sustainable Canmaking

A global aluminum can manufacturer sought to reduce natural gas consumption and lower the carbon footprint of its washer boiler system. The objective was to capture and reuse waste heat from the washer dryer’s exhaust airstream to preheat water for the washer, thereby decreasing boiler fuel demand without disrupting production or compromising equipment performance.

HeatTek engineered and installed a custom economizer heat exchanger system designed to recover thermal energy from the washer dryer’s exhaust stack. The economizer, mounted on a dedicated support frame, was positioned in-line with the exhaust stream to maximize heat transfer efficiency. The recovered heat was redirected to preheat incoming washer water, reducing the workload on the boiler. The system was integrated with the existing washer and boiler controls to ensure seamless operation, maintain process temperatures, and deliver consistent performance under varying production loads.

The new economizer system successfully reduced the amount of natural gas required to operate the washer boilers, lowering both operational costs and greenhouse gas emissions. The captured waste heat now contributes directly to process efficiency, translating into measurable energy savings and a reduced environmental impact. The project provided the customer with a practical, sustainable upgrade that supports long-term energy conservation goals while maintaining reliable production throughput.