Leading Poultry Manufacturer Saves Six Figures with ClearOil Continuous Filtration

Executive Summary

A leading manufacturer of breaded chicken products was losing significant revenue to rapid oil degradation and inefficient filtration. By implementing the ClearOil continuous filtration system, supplied by Lingwood, the manufacturer eliminated contaminant build-up, reclaimed usable oil from waste, and achieved six-figure annual savings, all while maintaining product quality and reducing overall oil consumption.

This case study explores how the right industrial frying filtration solution can transform production efficiency, lower costs, and deliver a measurable return on investment.

The Problem: Rapid Oil Degradation and Costly Inefficiencies

The manufacturer relied on rotary drum and static plate filters to maintain oil quality across its frying operations. Unfortunately, these systems clog quickly, leaving harmful contaminants behind in the oil.

These contaminants, including flour, crumb, and sugars from the breading process, accelerated oil degradation. The result was a costly cycle of problems:

• Increased oil costs due to frequent replacements
• Reduced product quality caused by degraded frying oil
• Higher cleaning times and greater labour demands
• Increased equipment wear, leading to additional maintenance costs

The manufacturer needed a reliable, cost-effective solution to improve oil quality, reduce waste, and bring production costs under control.

The Solution: The ClearOil Continuous Filtration System

Lingwood supplied the ClearOil system, a continuous filtration solution purpose-built for industrial frying operations. Designed to tackle the exact challenges this manufacturer faced, ClearOil delivers:

• Precision filtration that removes contaminants down to 1 micron
• Continuous crumb removal halting the build-up that accelerates oil degradation
• Oil reclamation, recovering usable oil from waste streams
• Saleable dry waste, turning a disposal cost into a potential revenue stream

Crucially, the ClearOil system was integrated seamlessly with the manufacturer’s existing equipment, minimising disruption and ensuring a smooth transition with no compromise to throughput.

The Results: Measurable Savings and Improved Quality

Following installation, the manufacturer saw immediate and sustained improvements across key performance indicators:

• Superior Oil Quality: Free Fatty Acid (FFA) levels held steady at 0.5, with Total Polar Materials (TPM) maintained at 8%, both well within optimal ranges for consistent product quality.
• Reduced Oil Consumption: Oil top-ups were cut by two-thirds, dramatically lowering ongoing purchasing costs.
• Six-Figure Annual Savings: The combination of reduced oil usage and effective oil reclamation delivered six-figure savings every year.

Conclusion: Turning Frying Costs into Competitive Advantage

The ClearOil system transformed the manufacturer’s frying process, cutting costs, improving product quality, and boosting operational efficiency. By addressing oil degradation at its source, the manufacturer turned a persistent financial drain into a streamlined, profitable operation.

With over 25 years of experience supplying the food processing industry, Lingwood delivers tailored filtration solutions backed by lifetime support and expert integration.

Ready to reduce your oil costs and improve frying efficiency? Contact Lingwood today to discover how the ClearOil system can transform your production.