Original situation
- Baseline data showed 136 kg of fuel per tonne of product from November 2024 to June 2025.
- Steam traps and control valves caused condensate build-up, uneven heat transfer and energy losses.
Objectives:
- Reduce fuel cost per tonne
- Ensure consistent quality and drying
- Implement the solution with no downtime
Technical modification
i-Kcal engineered and commissioned Jetomat TurboHeat® as a retrofit for the corrugator line, taking over from the pressure-reducing station and the steam traps (the five zone temperature control valves stay):
- Eliminated steam traps and steam losses
- Boosted internal steam velocity and heat transfer
- Delivered uniform surface temperature in the dryers and hot plates
- Installed with no downtime, so production continued uninterrupted
The Jetomat TurboHeat® retrofit resulted in ~15% fuel savings held over seven months (20.6% in the best month), elimination of steam traps, complete automation of heating and better drying quality — proving an effective way to raise both energy efficiency and process performance.
Results
| Period | Fuel (kg/tonne) | Saving vs baseline |
|---|---|---|
| Baseline (Nov 2024 – Jun 2025) | 136 | – |
| July 2025 | 113 | 16.9% |
| August 2025 | 108 | 20.6% |
Conclusion
This project shows that proven technology + expert engineering = measurable ROI. Jetomat TurboHeat, delivered by i-Kcal Systems, cut fuel use from 136 to 108 kg/tonne while maintaining consistent output and quality.
For corrugators, this is more than an efficiency upgrade — it is a step towards sustainable, cost-competitive growth.
