White Paper by Intprocon
In today’s industrial operations, energy waste and emissions are no longer just environmental concerns — they’re strategic and financial liabilities. Plants that produce feed, biomass, or processed grains release enormous amounts of thermal energy and VOCs every day. Most of it goes unused. Meanwhile, energy costs rise, carbon limits tighten, and CAPEX pressure builds.
EnerLoop™ by Intprocon is a closed-loop waste-to-energy solution designed to help industrial producers:
Whether you're planning an upgrade, facing VOC compliance mandates, or seeking better energy ROI, this paper explores how EnerLoop™ turns your plant’s losses into power — and your challenges into measurable gains.
What if your plant’s next energy source is already escaping through your vents?
Every hour, feed mills, biomass dryers, and grain terminals release thousands of BTUs in wasted thermal energy. Heated exhaust, volatile organic compounds (VOCs), and residual process heat are vented into the atmosphere — all while energy costs rise, emissions regulations tighten, and ESG expectations accelerate. In most plants, the heat you’re paying for is literally going up in smoke.
EnerLoop™ by Intprocon was built to change that. Designed for high-output agri-processors, EnerLoop™ captures exhaust heat and VOC-rich emissions, converts them into clean electricity, and reinvests that energy back into your operations. From drying systems to mixers and conveyors, your plant becomes its own power source — reducing energy bills, slashing emissions, and strengthening compliance with carbon and VOC targets.
Using ORC (Organic Rankine Cycle) or CHP systems, paired with environmental controls like scrubbers or RTOs, EnerLoop™ integrates directly into your plant’s thermal map. It helps you recover what you’re losing — and redeploy it where it counts.
If your operation is preparing for CAPEX upgrades, ESG reporting, or cost containment, this white paper will show you how EnerLoop™ turns waste into power — and regulatory burden into business advantage.
Industrial processors generate massive amounts of thermal energy — but most of it never gets used. In biomass dryers, pellet mills, and soybean crushing lines, heated exhaust is typically vented without recovery, resulting in significant energy waste.
According to the U.S. DOE, up to 50% of industrial process heat is lost as waste — often via stacks, vents, and exhaust ports. For plants spending hundreds of thousands annually on fuel or electricity, that’s money burned without return.
EnerLoop™ captures this escaping energy. By installing waste heat recovery units on dryers, coolers, or extruders, the system channels that heat into a conversion system such as an ORC (Organic Rankine Cycle), which converts it into usable electricity. That power is then reinvested in your operation—drying, conveying, or powering local controls—reducing overall utility costs and stabilizing load demand.
If your plant produces consistent high-temperature airflow but lacks heat recovery, EnerLoop™ doesn’t just reduce waste — it recovers it and puts it to work.
Emissions like VOCs (volatile organic compounds) aren’t just environmental risks — they often indicate lost process value. In feed and biomass plants, these compounds are typically released alongside hot air, forming an untapped opportunity for integrated recovery and control.
Regulations are tightening: in North America and Europe, VOC emissions limits are increasingly enforced, with noncompliance leading to fines, permit restrictions, and public disclosure. But here’s the good news — emissions and energy loss often share the same source.
EnerLoop™ tackles both. By integrating scrubbers, regenerative thermal oxidizers (RTOs), or other VOC mitigation tools alongside thermal recovery units, the system delivers a dual benefit: energy generation and compliance assurance. Waste heat is recovered; emissions are neutralized — all in one system.
This pairing turns an emissions line item into an ROI-driving opportunity. For ESG-driven processors, it also enables clearer carbon accounting, reporting alignment, and grant eligibility for circular-economy funding.
EnerLoop™ helps your plant meet today’s standards — and future-proof against tomorrow’s.
Every kilowatt recovered is one less you have to buy. And in thermal-intensive industries, even modest energy reuse can shift your bottom line — especially when tied directly to high-demand processes.
EnerLoop™ delivers clean power back to where it’s needed most: dryers, mixers, conveyors, or line control systems. Instead of relying entirely on grid or fossil fuels, plants operate using self-generated electricity — reducing exposure to energy price fluctuations and improving site-level energy independence.
According to industrial efficiency studies, heat recovery systems can cut total plant energy use by 10–20% — especially in operations running 24/7 with high heat loads. For feed producers or biomass plants spending $500K+ annually on energy, that’s real money saved without impacting performance.
What’s more, this model scales. As production grows, EnerLoop™ can be reconfigured to serve additional lines or support higher power demand — turning cost control into a strategic advantage, not just a savings line.
Whether you're applying for ESG grants, CAPEX approval, or evaluating decarbonization strategies, energy recovery is one of the most defensible and high-impact investments you can make.
EnerLoop™ supports technical and financial modeling during pre-project planning — including ROI calculations, emissions reduction potential, and carbon offset projections. This allows Engineering Directors and ESG Managers to build stronger business cases, backed by real-world recovery data and environmental outcomes.
Many carbon disclosure frameworks (like CDP or GHG Protocol) now reward on-site energy generation and waste reduction. Integrating EnerLoop™ can improve your sustainability score, lower Scope 1 emissions, and position your operation for future regulatory alignment — while reducing hard costs at the same time.
Put simply: EnerLoop™ turns energy loss into a CAPEX justification tool — with performance and compliance wins in one package.
Most organizations view emissions and energy costs as separate challenges. But EnerLoop™ treats them as one problem with one solution: waste energy isn’t just a symptom — it’s a resource waiting to be reused.
By capturing heat, converting it into electricity, and controlling emissions simultaneously, EnerLoop™ creates a closed-loop system aligned with circular-economy goals. It integrates into your plant’s natural process rhythm, not as an interruption, but as an enhancement.
From layout design to OEM equipment coordination, EnerLoop™ is more than a one-time upgrade — it’s a platform for sustainable operations that evolve with your plant’s growth.
And in a competitive world where margins are tight and carbon targets matter, closing your energy loop may be the most valuable shift you make this decade.
Every ton of biomass dried, every batch of feed extruded, and every cycle of heated air in your plant creates a hidden cost — not just in dollars lost, but in energy wasted, emissions unmanaged, and potential unrealized.
EnerLoop™ by Intprocon changes the equation. It captures that waste heat, converts it into clean power, controls VOCs, and reinvests energy back into the heart of your plant — all while improving your carbon profile and strengthening ESG performance.
This isn’t just about cost savings — it’s about smarter engineering. Smarter planning. Smarter production.
What could your plant achieve if your biggest loss became your next source of power?
From CAPEX justification to long-term resilience, EnerLoop™ turns your plant’s most ignored byproduct into a strategic asset — one that pays for itself in power, performance, and credibility.
The heat’s already there. The question is: will you keep letting it go — or finally put it to work?