Customer Overview
FreshHarvest Foods Ltd., based in Norfolk, UK, specializes in pre-packaged vegetable processing and ready-to-eat frozen vegetable products, with a daily output of approximately 15 tons, supplying major supermarkets and catering channels.
Challenges (Pain Points)
Traditional steam boilers have slow startup times (40–60 minutes), delaying production line preparation.
Steam quality was inconsistent, containing oil and impurities, affecting pasteurization uniformity, leading to a batch rework rate of ~3.2%.
High energy consumption; fuel and maintenance costs accounted for over 8% of production costs.
The facility required stricter food safety compliance and traceability; the existing system could not fully support automation and recording.
- Solution (Provided by JESSIA)
Equipment: JESSIA-G150 (150 kg/h steam output, 0.8 MPa rated pressure, natural gas heating with low-NOx burner)
Supporting Systems: Water softening unit + PLC intelligent touchscreen control + remote monitoring module (4G) + condensate recovery unit
Implementation: Complete replacement of old boiler, insulated steam pipeline installation, integration with factory DCS, operator training, 6 months free technical support.
Implementation Timeline
Site survey & requirements confirmation (Week 1)
Equipment manufacturing & dispatch (Weeks 2–4)
On-site installation & pipeline modification (Week 5)
Commissioning, PQ validation & staff training (Week 6)
Full production operation (Week 7)
On-Site Results (First 3 Months)
Startup Time: Reduced from 40–60 minutes to 5–8 minutes (instant steam), improving early-shift production readiness.
Energy Consumption: Thermal efficiency optimized, fuel consumption decreased by ~28%.
Production Efficiency: Pasteurization batch pass rate increased, rework reduced from 3.2% to 0.6%, effective line capacity increased 18–22%.
Maintenance Costs: Less scaling and post-treatment, monthly maintenance hours reduced ~40%.
Data & Compliance: PLC automatically records temperature and pressure curves, meeting food safety traceability requirements.
Customer Testimonial (Fictional)
“Since installing the JESSIA steam generator, we can produce an extra shift of finished products daily. Steam quality is consistent, energy consumption is lower, and the automated recording system has greatly reduced our quality risks.” — Operations Director, FreshHarvest Foods Ltd.
Key Benefits
Increased production line utilization and output (+18–22%)
Reduced fuel costs (~28%) and maintenance expenses (~40%)
Reduced rework and quality risks (from 3.2% to 0.6%)
Compliance with food safety traceability and automated monitoring requirements
Visual Display Suggestions for Web or Brochure
Project Overview (Customer, Location, Capacity)
Problem → Solution → Result comparison chart
Energy-saving curve (% reduction)
Customer testimonial with photo or title (marked as sample/demo if needed)
