01.09.2025

More Than a Storm in a Glass of Water: Efficiency in Meat Processing That Pays Off

The meat industry faces a twofold challenge: rising production and energy costs on one side, and increasingly stringent demands for sustainability and resource efficiency on the other. Added to this is a shortage of skilled workers, making automation more important than ever. Companies that optimize processes today not only secure cost advantages but also safeguard their competitiveness for tomorrow. VETEC ANLAGENBAU demonstrates how modern system solutions make this possible.

In July 2025, German consumers paid an average of around 19% more for beef than a year earlier. Over the long term, and across the EU, inflation for meat and sausage products has been even more pronounced, in some cases exceeding 40% since 2015. These costs pressures ripple across the entire production and supply chain. Meanwhile, retailers continue to demand moderate prices, intensifying competition among manufacturers. Political measures such as the German federal government's planned industrial electricity price, may provide temporary relief-but not for every company. It’s no surprise, then, that many businesses have a rather pessimistic outlook. Technologies that deliver efficiency gains with short payback periods are now more important than ever.

From Flow Simulation to Customized Drying

When engineering customized air systems for the fundamental drying process of meat and sausage products, the long-established Lower Saxony company VETEC ANLAGENBAU draws on decades of project experience combined with AI-supported flow simulations. This results in field-tested system designs such as the award-winning AEROMAT ^{CROSS POWER} for lying products like bacon, beef jerky, and dog treats. This system features horizontal air flow with patented nozzle geometry, achieving air speeds up to four times higher than conventional systems. "Where other systems take considerably longer to dry, and the raw material is either over-treated in some places or remains under-supplied in hard-to-reach areas, we rely on an individually controllable and product-adaptable alternating air flow using innovative injection technology," explains Andreas Sauer, Managing Director of Sales at VETEC ANLAGENBAU.

For products such as hot dogs, wieners, or mortadella, the proven and continuously optimized interchangeable flap system in the classic AEROMAT ensures dynamic air circulation and exceptional uniformity.

Consistent Air Distribution for Optimal Yield

Consistent airflow maximizes yield for both hanging and lying products while maintaining uniform quality – regardless of product position or dense loading. These comparable conditions minimize localized hot or cold spots and ensure a stable, reproducible process for food manufacturers, saving money. "Overdrying leads to significant weight losses, which then have to be compensated for with costly meat additives to meet packaging requirements," emphasizes Andreas Sauer.

From Power Units to Heat Exchanger – Savings Down to the Last Detail

With additional technical details, VETEC's systems achieve further energy savings. For example, IE4 motors with frequency converters are installed on specially designed fans with Energy Efficiency Class 1, achieving increased efficiency in the air-drying drive. Furthermore, optional heat recovery concepts reduce energy consumption by up to 30% by preheating the fresh air using waste heat. Flow-optimized components such as the flat-tube heat exchanger with a special design halve pressure resistance compared to conventional technologies. Pre-cooling with filtered and free outside air in intensive cooling systems also ensures optimal utilization thanks to the automatic calculation of the usable outside air energy. The drying process to a customer-defined humidity level using a metered fresh air flap and reduced exhaust air flow significantly reduces heating costs and leads to less weight loss.
With heat generation and cooling accounting for up to 60% of total energy use in meat processing, the savings potential is significant.

Economics and Ecology Hand in Hand

Technological opportunities also lie dormant in the exhaust gas treatment of hot and cold smoke systems, offering both economic benefits and compliance with sustainability requirements. VETEC ANLAGENBAU has further developed the biofilter concept as a method for cleaning exhaust air containing carbon and odorous, using a sprinkler system and wood chips: The ECO ^{AIRCLEAN F} system requires minimal maintenance and has lower operating costs compared to technical alternatives. "Thanks to the long service life of the wood chips-up to ten years-there is virtually no wear and tear. Wastewater treatment is unnecessary, no cleaning chemicals are required, and upstream and downstream systems such as air scrubbers or activated carbon are not needed," explains Andreas Sauer.

Conclusion: Efficiency by Design

VETEC ANLAGENBAU’s solutions prove that energy-intensive processes can be both economically competitive and environmentally responsible. Precise airflow, shorter drying times, and resource-saving technologies create measurable efficiency gains that directly impact the bottom line.