Research Project Information

Research Project Summary Information

Consolidated high temp heat recovery(15746)

Frito Lay, Inc.


Frito-Lay, Inc. seeks to demonstrate the recovery and application of heat from distributed sources in a collective manner. Combustion gases from 14 different sources in the plant will be combined into a single, common stream and ducted to a waste heat recovery steam generator (HRSG) producing high pressure steam that will directly offset loads on the existing boiler. Frito-Lay’s plant in Binghamton, New York, employs about 250 people. Electrical service is provided by NYSEG (New York State Electric & Gas Corp.) at an annual cost of approximately $1.4 million, including a Power for Jobs allocation. Fuel expenses, primarily for natural gas, exceed $4 million annually.

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Project Description

This approach is unique in its scope and execution; competing technologies generally focus on the individual device and involve regeneration methods of preheating combustion air or the product flow itself. The project will be conducted across seven tasks that will comprise the actual demonstration. It is anticipated that the proposed work can be completed within 12 months.


Frito-Lay, Inc. will benefit from the savings in fuel consumption and related emissions. The actual energy savings will be dependent on production activities at the plant and details of the installation. Based on the available production records and an assumed runtime of 120 hours per week, fuel savings should approach 30,000 dekatherms annually under nominal conditions. At the plant’s present cost of natural gas ($13 per dekatherm), this equates to almost $380,000 per year. Other entities within the state are likely to benefit from this demonstration. New York State ranks among the top 15 states in food production and distribution. Many other industries across the state that generate high temperature waste streams (metal treating, etc.) could also benefit from a demonstration of this technical approach.

Project Results


Frito Lay, Inc.
10 Spud Ln Attn: Tim Polman
Binghamton, NY 13904

Principle Investigator

John DeFrees

Universities Involved


Project Type:

On-site Process Improvement

Technologies Types:

Waste Heat

NYSERDA Contact Information

Miriam Pye


R&D - Mfg Tech & On-Site Pwr

Contract Details

Start Date: 5/4/2010 1
Project Status: Active
Contract Number: 15746

Last Updated: 7/30/2014