When we work on processing sites, the conversation usually comes back to one thing. The boiler has to work. Every day, without becoming a problem for the plant.
That was the starting point at AFFCO Horotiu.
This is a high-throughput meat processing site where steam demand shifts daily with production. It is not a steady load. Some days are heavier than others, and the system needs to respond without hesitation.
Moving away from gas in that kind of environment is not just about reducing emissions. It is about maintaining performance, reliability, and continuity.
The Challenge: Replacing Gas in a Variable Load Environment
At Horotiu, steam demand is directly tied to what is happening on the processing floor. That creates a few clear challenges:
- Load changes throughout the day
- Seasonal peaks increase pressure on the system
- Downtime is not an option
Gas has traditionally handled this well because it is flexible and predictable. The problem is that the wider context has changed. Pricing is less stable, and emissions now carry a real cost.
The brief was simple on paper. Replace natural gas with a renewable energy source, without introducing risk or operational complexity.
The Solution: 8MW Biomass Boiler Using Wood Pellets
We worked with AFFCO to install a wood pellet boiler system, supported through EECA’s GIDI programme.
At the core of the system is an 8MW biomass boiler, designed for industrial-scale performance. Key components include:
Automated fuel handling from delivery through to combustion
Pneumatic conveying for consistent fuel feed
Control systems that adjust output in real time based on steam demand
Minimal operator input during normal operation
The goal was not to introduce something unfamiliar. It was to deliver a system that behaves like gas, but runs on renewable biomass fuel.
Day-to-Day Operation
A common question is what this looks like in practice.
At Horotiu, the process is straightforward. Wood pellets are delivered in bulk and stored onsite. From there, the system manages fuel feed, combustion, and output automatically.
Steam output adjusts based on plant demand, without manual intervention.
Operators are not managing the boiler throughout the day. In terms of operation, it feels much closer to gas than most expect.
The system can ramp up and down as needed, which is critical in a processing environment where demand is constantly changing.
The Outcome
The real test is not installation. It is performance under normal operating conditions.
“We’ve installed a new carton buffer and carton palletiser, and that’s allowed us to redeploy a number of staff to other parts of the operation where we were short. This helped with efficiencies and savings on costs.” – Trevor Bennett, Horotiu Plant Manager
Project Results
Metric: Previous fuel
Outcome: Natural gas (replaced by biomass boiler)
Metric: Boiler capacity
Outcome: 8 MW biomass (wood pellet) boiler
Metric: Fuel replacement
Outcome: 100% of gas displaced (fully replaced with wood pellets)
Metric: Annual emissions reduction
Outcome: [Insert: tonnes of CO₂-e avoided per year]
Metric: Energy cost impact
Outcome: [Insert: % cost saving or $ annual saving]
Metric: Operational performance
Outcome: Fully automated, approved for unattended operation; minimal operator attendance required; automated start up, shutdown, and steam network warm up
Metric: Load flexibility
Outcome: Handles daily and seasonal demand variation
Metric: Fuel supply
Outcome: Wood pellets supplied by Nature’s Flame (Taupō)
Why This Project Matters
Many of the straightforward conversions have already been completed.
What remains are sites with variable load profiles and limited tolerance for disruption.
Horotiu is a clear example of what is possible in that space. Demand changes daily, yet the system continues to perform without becoming a point of concern for the plant.
This shows that biomass boiler systems can operate reliably in real-world, variable environments.
See the System in Action
[Insert video link]
Seeing the system running answers most practical questions, especially around automation and day-to-day operation.
Independent Case Study
This project is also being featured as an EECA case study, providing an independent view of system performance.
That matters for organisations considering a similar transition. It is not just a supplier claim. It is verified in a real operating environment.
The Takeaway
This project comes down to a few simple outcomes.
- The system does the job gas used to do
- It handles variable demand without issue
- It runs as part of normal plant operations
- It does all of that using renewable wood pellet fuel
That is the benchmark. Not just installing a system, but delivering one that works reliably once it is live.
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