₱110,000 a month back in your pocket.From day one.
For Philippine beverage bottlers — juice, RTD tea, bottled water. Your line runs hot and cold at once: the tunnel pasteuriser heats the product then chills it within metres — one electricity bill, no LPG boiler, financed by the bank, paid for out of the saving. The heat you dump off the cooling zones today is the heat you buy back for CIP.
The tunnel pasteuriser heats the product. Then chills it within metres.
A bottling line runs two opposing thermal jobs at the same time: the tunnel pasteuriser raises the filled bottle to 60–72 °C to kill spoilage organisms, then the cooling zones drop it straight back down — while CIP wants 65–85 °C all shift and cold-fill product wants chilled water. Today those two jobs run on two separate bills — Meralco to throw the heat into a cooling tower, the LPG man to buy the same heat back.
Cold fill and tunnel cooling are non-negotiable — and your chiller is the weak link
Cold-fill product and the tunnel cooling zones need chilled water on demand, and process / room cooling runs all shift. Most PH bottlers run an ageing R404A chiller at COP ~2.8 with an F-gas phasedown clock on the asset register and service prices rising every year. Karnot iCOOL CO₂ holds the same duty at COP 4.2 (Oak Ridge National Laboratory validated) — 40% less electricity on the cold side, and the heat it removes is the heat your CIP loop needs.
The LPG boiler is your biggest controllable cost — and it's optional
CIP caustic and acid loops (65–85 °C), the tunnel pasteuriser heating zones (60–72 °C) and bottle warming burn roughly 22,000 kg of LPG a year on a 50,000 L/day plant — about ₱1.87M/yr. But the heat your product and tunnel cooling zones give up, captured at the iCOOL CO₂ gas cooler at 75–90 °C, covers the CIP and pasteuriser load. The boiler is retired, not replaced. No flame, no flue, no insurance loading.
Chill the product. Bank the heat. Retire the boiler.
A heat pump moves heat rather than creating it. When iCOOL chills your product and the tunnel cooling zones, the heat removed is delivered to the hot side at 75–90 °C — exactly what the CIP loop and the pasteuriser heating zones need. Your filler, capper and tunnel pasteuriser stay — we replace the utilities around the line, not the line.
iCOOL CO₂
Cold fill, tunnel cooling and process cooling at COP 4.2. The gas cooler delivers 75–90 °C hot water from the same compression cycle. A1 safety class — the same CO₂ that carbonates the drink.
iHEAT R290
CIP and tunnel pasteuriser duty. Drop-in replacement for the LPG boiler. Outdoor install, sealed 1.4 kg charge, EN 378 compliant — no boiler room, no flame on site.
iSTOR PCM
Thermal battery on both sides. Hot: tunnel heat banked for the CIP washout. Cold: cold fill and the cold store ride through a PH brownout with zero compressor load. The shift keeps running through the outage.
iSAVE + iVOLT
iSAVE meters every duty — monthly IPMVP Option B report to your accountant and your lender. iVOLT zero-export solar on the plant roof cuts the remaining grid draw a further 30–50%.
50,000 L/day plant. A real number per litre.
Modelled on a 50,000 L/day Philippine beverage bottling plant (juice, RTD tea or bottled water) — CIP, the tunnel pasteuriser, product cold fill and process cooling. Your plant might be 10,000 L/day or 200,000 L/day — the per-litre economics hold.
| Annual figure · 50,000 L/day | Today · boiler + old chiller | Karnot platform | You stop paying |
|---|---|---|---|
| Process heat (CIP + tunnel pasteuriser) | ~22,000 kg LPG/yr | 0 kg · recovered heat | ₱1.87M/yr |
| Product + tunnel cooling | COP 2.8 · R404A | COP 4.2 · CO₂ GWP 1 | ₱980K/yr |
| Total heat + cooling bill | ~₱2.85M/yr | ~₱1.0M/yr | −64% / ~₱1.85M |
| Scope 1 + refrigerant exposure | ~52 tCO₂e + GWP 3,922 | GWP 1 & 3 · natural | ~62 tCO₂e/yr |
| Total investment (VAT-inc) | (already paid) | ~₱2.8M | 1.5 yr cash payback |
The cash flow. Plain and dull.
CAPEX of ~₱2.8M, financed under a green loan at ~7.5% p.a. over 7 years. The monthly saving (~₱154K) covers the monthly loan payment (~₱44K) more than three times over. Net cash in pocket from day one.
We don't guess the saving. We calculate your thermodynamic minimum.
Pinch analysis maps every hot stream in your plant (product that must cool, tunnel cooling-zone heat that must leave) against every cold stream (CIP and pasteuriser water that must heat) and computes the three numbers that define your energy performance. A bottling plant is the textbook case — the analysis practically writes itself.
The absolute least boiler energy your plant needs after maximum heat recovery. If your boiler burns more than this — and in every plant we have surveyed, it does — the difference is pure waste.
The absolute least chiller energy required after recovery. Everything your chiller removes above this is tunnel heat you paid to make and then paid again to throw away.
The bottling-plant bottleneck temperature. Above it: heat deficit. Below it: heat surplus. A heat pump is the only utility that moves surplus heat from below the pinch to the deficit above it — which is why the saving is 64%, not 15%.
New to pinch analysis? We wrote the plain-English guide — no jargon, no PhD required, with worked composite curves explained in pictures. Then commission a Level 1 Energy Survey (₱90K, refunded in full on install) and we run the pinch study on your actual line log.
You pay nothing up front. The bank does.
Three Philippine banks run green-loan programmes built for exactly this kind of project. The monthly saving covers the loan payment more than three times over. Net cash flow goes up from day one.
These are loans, not grants. Plus BOI Pioneer Income Tax Holiday under RA 11285 — energy-efficient manufacturing qualifies. Karnot files the loan, the BOI registration, the building permits and the monthly IPMVP M&V report your lender wants to see as part of project scope. You sign at the bank window, not before.
Download the Bottling Plants Application Brief
A 4-page application brief and a 10-slide deck — both ready to share with your plant manager, your accountant or your board.
4-Page Application Brief
A4 portrait PDF · print-ready. Hero, cash strip, problem + architecture, four products, the 50,000 L/day numbers table, pinch analysis, bank finance, founder quote.
10-Slide Sales Deck
16:9 landscape PDF. The complete presentation — problem, architecture, four boxes, the bill, cash flow, bank finance, pinch analysis, refrigerant trilemma, next steps.
Frequently Asked Questions
How much can a Philippine beverage bottling plant save?
A modelled 50,000 L/day Philippine beverage bottling plant (juice, RTD tea or bottled water) saves approximately ₱1.85M per year — a 64% reduction in the combined heating and cooling utility bill. Today's setup (LPG boiler ~₱1.87M/yr for CIP and the tunnel pasteuriser + chiller electricity and mains-water cooling ~₱980K/yr) costs about ₱2.85M/yr; the Karnot integrated platform delivers the same duties for about ₱1.0M/yr of electricity. With a 7-year green loan at ~7.5% p.a., the monthly saving (~₱154K) exceeds the loan payment (~₱44K), leaving roughly ₱110,000 net cash per month from day one. Plants from 10,000 to 200,000 L/day scale proportionally.
How can the same machine chill the product and heat the CIP loop?
A heat pump moves heat rather than creating it. A bottling line runs hot and cold at once: the tunnel pasteuriser heats the filled bottle then chills it within metres, while CIP wants 65–85 °C and cold-fill product wants chilled water. When Karnot iCOOL CO₂ chills the product and the tunnel cooling zones, the heat removed is rejected at the CO₂ gas cooler at 75–90 °C — exactly the temperature the CIP loop and the pasteuriser heating zones need. Today that heat goes into a cooling tower (wasting mains water) while an LPG boiler buys the same energy back. The Karnot platform transfers it across instead: chill the product, bank the heat, retire the boiler. Your filler, capper and tunnel pasteuriser stay — we replace the utilities around the line, not the line itself.
Can a heat pump reach pasteurising and CIP temperatures?
Yes. The iCOOL CO₂ gas cooler delivers 75–90 °C hot water and the iHEAT R290 cascade delivers 60–85 °C at COP 4.0+ in Philippine ambient — covering CIP loops (65–85 °C), the tunnel pasteuriser heating zones (60–72 °C) and bottle warming, which together are roughly 70% of the plant's thermal demand. Tunnel pasteurisation of juice, RTD tea and similar beverages sits comfortably inside heat-pump reach, so the LPG boiler is retired, not merely downsized — and the combustion, the flue and the insurance loading go with it.
What is pinch analysis and why does it matter for my bottling plant?
Pinch analysis maps every hot stream (product that must cool, tunnel cooling-zone heat that must leave) against every cold stream (CIP and pasteuriser water that must heat) and computes QHmin and QCmin — the absolute minimum heating and cooling your process needs after maximum heat recovery. Everything above that minimum is waste. In a bottling plant the pinch point sits around 35 °C, and a heat pump is the only utility that can move surplus heat from below the pinch to the deficit above it — which is why savings reach 64% rather than the 10–15% a heat-exchanger-only retrofit delivers. Start with the plain-English pinch guide, then commission a Level 1 Energy Survey (₱90K, refunded on install) and we run the pinch study on your actual line log.
Is CO₂ refrigerant safe for a beverage plant?
Yes — CO₂ (R744) is an A1 safety class refrigerant: non-toxic, non-flammable, food-safe, and literally the same gas dissolved in your carbonated drinks. GWP of 1 with no F-gas phasedown exposure. Compare the legacy options: R404A and R134a chillers have GWP up to 3,922 with quota-driven service prices rising every year, and industrial ammonia is efficient but toxic — exclusion zones, specialist technicians, insurance loadings. Karnot iHEAT R290 (propane) sits outdoors with a sealed 1.4 kg charge under EN 378. Nothing on the asset register carries a phasedown date or an exclusion zone.
What happens to cold fill and my cold store during a brownout?
The iSTOR PCM thermal battery carries cold fill and the cold store through 8–12 hours of grid outage on stored cooling alone — no compressor, no generator. Chilled water keeps the cold-fill product and process cooling at temperature so the shift keeps running through the outage. The same battery banks recovered tunnel heat between CIP cycles so the CIP loop is hot when the washout calls for it: the heat pump charges the hot buffer, the plant draws on demand.
Does this work for water, juice and RTD tea lines?
Yes — the model scales across the beverage mix. A bottled-water line leans cold (cold fill plus process and room cooling) with lighter CIP, while juice and RTD tea lines add the tunnel pasteuriser and heavier CIP — which makes the simultaneous heating-and-cooling case even stronger because the recovered tunnel and product-chill heat goes straight into CIP and the pasteuriser heating zones. Karnot iCOOL CO₂ handles the cold side and iHEAT R290 delivers 60–85 °C to the hot side; we size on your daily volume and line schedule. Economics scale 10,000–200,000 L/day.
What financing and incentives are available?
Three Philippine banks run green-loan programmes that fit bottling-plant CAPEX: DBP SEFP (~6.5–8% p.a., 70–80% LTV, industrial energy-efficiency priority), LandBank SEILP (~7% p.a., strong for regional producers), and BPI SDF (~1–1.5% below standard SME rates). Most installs also qualify for BOI Pioneer status and an Income Tax Holiday under RA 11285 as energy-efficient manufacturing. Karnot files the loan application, the BOI registration, the building permits and the monthly IPMVP M&V report your lender wants — as part of project scope.
Want the numbers for your bottling plant?
Send us your daily volume (L/day), 12 months of LPG + electricity bills and your line + CIP schedule. We come back with a sized system, your QHmin and QCmin, projected saving, payback — and the bank application ready to sign.