Solar for Process Heat

Replacing Gas Boilers in Food and Beverage Manufacturing

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Summary

Food and beverage (F&B) manufacturers rely heavily on process heat for cooking, cleaning, and pasteurisation energy that's traditionally supplied by natural gas boilers. As gas prices rise and decarbonisation pressures grow, these systems have become both a cost and carbon liability.

Agile Energy provides solar and battery solutions that displace or replace gas-fired boilers using solar thermal, solar PV, and smart storage systems. Our integrated approach reduces emissions, stabilises energy costs, and strengthens operational resilience, without compromising hygiene or production reliability.

The Challenge

Process heat often represents 20-60% of an F&B facility's total energy use. Gas- fired boilers have long dominated because of their temperature range and reliability, but they expose businesses to price volatility, carbon costs, and supply risk. In Australia, this challenge is amplified by fluctuating gas markets and tightening emissions targets.

Agile Energy helps manufacturers reduce gas dependence through renewable process heat solutions integrating solar technologies, energy storage, and advanced controls tailored to each facility's operational profile.

Solar Pathways for Process Heat

Agile Energy designs solar systems that meet a wide range of temperature and operational needs:

• Solar Thermal Systems: Efficiently deliver low to medium-temperature heat (30-150°C) using evacuated tube or flat-plate collectors. Ideal for CIP systems, washing, and boiler feedwater pre-heating.

• Concentrated Solar Thermal (CST): Provides higher temperatures (150-400°C) for steam generation, cooking, and sterilisation. Thermal oil or molten salt storage extends operation into the night.

• Solar PV + Electrified Heat: Combines PV generation with electric boilers or heat pumps. Suited for facilities with rooftop space or a desire for fast deployment.

• Hybrid Systems: Integrate multiple technologies with storage and smart controls to deliver round-the-clock reliability and maximum solar utilisation.

These systems can displace 20-50% of annual gas use, or more when paired with thermal storage and load optimisation.

Storage & Integration

Thermal storage, via insulated water tanks, pressurised systems, or molten salts, ensures solar heat is available even when the sun isn't. Agile integrates these systems directly with existing boiler networks, allowing solar to supply base-load demand while gas remains as a flexible backup.

Closed-loop heat exchangers and automated controls maintain food safety standards, consistent steam quality, and seamless transitions between solar and conventional systems.

Commercial Models & Returns

Agile Energy provides flexible finance and ownership structures:

• Power Purchase Agreements (PPAs): No upfront cost; pay per unit of useful heat delivered

• Energy-as-a-Service: Agile owns, operates, and maintains the system, offering predictable pricing

• Direct Ownership: For businesses seeking long-term savings and full control

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Typical outcomes for Australian F&B facilities include:

• 20-50% reduction in gas consumption

• Payback periods between 5-8 years

• Up to 40% scope 1 emissions reduction

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Implementation Roadmap

1. Feasibility & Audit: Map process heat demand, temperature bands, and available solar resource

2. System Design: Model energy yield, thermal storage, and financial performance

3. Deployment: Modular rollout minimising operational disruption

4. Monitoring & Optimisation: Continuous performance tracking and predictive maintenance

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Case Example

A regional dairy processing plant using 12,000 GJ/year of gas partnered with Agile Energy to deploy 1,200 m† of solar thermal collectors, 400 kW of PV, and 500 kWh of storage. The system displaced 35% of annual gas use, cut emissions by 900 tonnes, and achieved an IRR of 14% under a PPA structure

Why Agile Energy

• Proven expertise in industrial solar integration

• End-to-end delivery from audit and design to finance and operations

• Australian-based support and maintenance

• Flexible commercial options aligned to performance

Conclusion

Replacing gas boilers with solar-driven process heat is no longer a future ambition - it's a practical, profitable pathway today.

Agile Energy delivers tailored solutions that reduce energy costs, emissions, and risk for Australian manufacturers, empowering the F&B sector to achieve cleaner, more resilient operations.

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