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MEGAFOOD PROCESS EXPANSION

LONDONDERRY, NEW HAMPSHIRE

CHALLENGE

B2Q was retained by MegaFood, formerly FoodState, to analyze the process heating and utility systems at their dietary supplement manufacturing facility in preparation of a process expansion. B2Q was subsequently hired as the prime design engineer for multiple process expansion projects.

OPPORTUNITY

B2Q designed a new process piping loop for the existing bioreactor to convert from steam to hot water in order to improve safety and efficiency. The conversion unlocked more precise temperature control which saved energy previously used due to overheating and re-cooling. B2Q also optimized the existing drying process to increase capacity. B2Q led the design team, including architects and electrical engineers, for a new 75HP steam generator installation to support the process expansion.

RESULT

B2Q oversaw the design, specification, bidding, and installation of the new steam generator. B2Q also optimized the existing production drying process, increasing drying capacity by 50%. The bioreactor conversion saved MegaFood over 10,000 therms/year from cleaning and condensate savings.

Market:

Industrial

Services:

Project Design

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The ETIC RCx project was an outstanding success, delivering verified energy savings and operational improvements that exceeded UMass Lowell’s expectations. The project achieved impressive annual cost savings—10% higher than initially projected—while reducing energy intensity by 14% for UMass Lowell’s third-largest utility account.

Beyond cost savings, the initiative delivered significant environmental benefits, cutting annual carbon emissions by 530,000 lbCO2e. Additionally, it enhanced lab safety through robust lab pressurization tracking and the recalibration of all terminal devices.

This success was made possible through the unwavering collaboration between UMass Lowell, B2Q, and NGRID, demonstrating the power of partnership and a shared commitment to cost efficiency, sustainability, and operational excellence.

Daniel Abrahamson 
University of Massachusetts Lowell

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