Project overview
Resalta delivered a comprehensive renovation of the heating and cooling system at the production facility of Juteks d.o.o., part of the Beaulieu International Group, in Žalec, Slovenia.
The project focused on replacing outdated heating infrastructure and improving the overall efficiency of the site's energy system by integrating heating and cooling processes. The solution was delivered under a 10-year DBOT ESCO contract, enabling the client to modernise critical infrastructure and reduce operating costs without upfront capital investment.
The renovation was completed between June and October 2025, with the key installation works carried out during the facility’s 14-day summer shutdown period.
Results
The renovation delivered significant improvements in energy efficiency and operational reliability.
Key results include:
- Up to 70 % reduction in annual natural gas consumption
- reduced electricity consumption for cooling tower operation
- lower make-up water consumption in cooling towers
- improved reliability of the technological cooling system
- 140 tonnes of CO₂ emissions avoided per year
In addition to the measurable savings, the new system provides higher redundancy and reduces the risk of production downtime.
Financing model
The project was implemented under a 10-year DBOT ESCO contract.
Under this model, Resalta financed, designed, implemented and operates the energy system. The client benefits from modernised infrastructure and reduced energy costs, while payments are linked to the realised energy savings.
The Challenge
Prior to renovation, space heating for the production facility and parts of the technological process relied on a combined natural gas and oil boiler installed in 1989 with a thermal capacity of 1,600 kW. The system operated with low efficiency and limited control capabilities.
At the same time, technological cooling was provided by three water-cooled chillers with a total cooling capacity of 2 MW, with condenser heat rejected through open cooling towers. Significant amounts of thermal energy from the cooling process were therefore released into the atmosphere instead of being reused within the facility.
The objective of the project was to redesign the heating and cooling system in a way that would improve efficiency, reduce energy consumption and increase the reliability of the technological cooling process.
Energy Feasibility Study
The project began with a comprehensive energy feasibility study conducted by Resalta in 2023.
The study included detailed measurements and analysis of the site's energy and material flows, including:
- thermal energy
- electricity consumption
- process water usage
- cooling energy flows
- compressed air consumption
Cooling energy measurements were performed at the cooling towers alongside simultaneous measurements of thermal energy in the heating system.
Based on this analysis, Resalta proposed an integrated solution centred around a water-to-water heat pump, allowing the facility to simultaneously produce cooling energy for technological processes and thermal energy for the heating system.
The feasibility study also defined the technical scope of the renovation, equipment capacities, spatial integration of the new system and the overall investment framework.
The solution
Following the preparation of project documentation, renovation works began in June 2025.
The new system is centred around a water-to-water heat pump with a heating capacity of 1,030 kW, operating at a condenser temperature regime of 70/60 °C and an evaporator regime of 22/17 °C.
The heat pump integrates directly into the existing cooling infrastructure and enables a circular energy process within the facility:
During the heating season, the heat pump extracts heat from the technological cooling process and thermally lifts it to supply heating for the production facility and administrative buildings.
The system simultaneously provides cooling for technological processes, reducing the operating hours of the existing cooling equipment.
In the event of a cooling system failure, the heat pump can switch to chiller mode and provide priority cooling for the production process.
To ensure reliable operation, a new condensing dual-fuel gas-oil boiler with a capacity of 1,200 kW was installed as a backup and bivalent heat source.
More than 90 measuring devices were installed across the system and integrated into a new central control system, enabling real-time monitoring, performance optimisation and data-driven operational decisions.
Implementation
One of the key challenges of the project was the limited time available for construction works inside the production facility.
All critical works had to be completed during the plant’s collective summer shutdown, providing only a 14-day window for installation and integration of the new system.
Despite this constraint, the system was successfully installed, integrated and commissioned within the planned timeframe and investment framework. The installation has been operating reliably since October 2025.