T‑FIT® Insulation: Enhancing Safety, Quality, and Energy Efficiency at KMF Cooperative

High‑performance T‑FIT® Hygiene and T‑FIT® Process insulation dramatically reduces condensation risks and cross‑contamination in dairy production.

Condensation is a persistent threat for food and beverage manufacturers, often leading to product spoilage and brand damage. When KMF Cooperative (India’s second‑largest dairy cooperative) identified this issue, they partnered with Zotefoams to install T‑FIT® insulation, achieving substantial safety, quality, and cost benefits.

During a recent external audit by the Food Safety and Standards Authority, cracks in the existing polyurethane foam and nitrile rubber pipe insulation were found, allowing moisture ingress and creating a breeding ground for bacteria and fungi. The switch to T‑FIT® Hygiene and T‑FIT® Process addressed these concerns instantly.

Why Condensation Happens in Dairy Facilities

In chilled and frozen food production, fluctuating ambient temperatures and variable line flows cause pipe surfaces to fall below the dew point. Droplets then form, transferring impurities into the product stream. For KMF, temperature swings ranged from –5 °C during ice‑cream production to 90 °C during steam and Clean‑in‑Place (CIP) procedures, leading to energy loss and lye buildup on tubes.

Purpose‑Built for High‑Demand Environments

Working closely with the T‑FIT team in India, KMF replaced the old insulation with T‑FIT® Hygiene (ZOTEK F, fine closed‑cell PVDF) and T‑FIT® Process (ZOTEK N, tough nylon). The proprietary three‑stage manufacturing process ensures:

• Ease of cleaning and no need for PPE or containment during installation.
• Immunity to most chemicals, wide temperature tolerance, and excellent flammability & UV resistance.
• Particulate‑free guarantee for aseptic production.

T‑FIT® Hygiene was installed on the chiller and ice‑cream filling lines to stop condensation, while T‑FIT® Process, rated up to 200 °C (EN14707), protected steam and CIP lines from heat spikes.

Results & Benefits

Key outcomes include:

• Heat‑loss reductions of 96 % on a 3‑inch CIP line and 80 % on a 2.5‑inch chiller line.
• Significant energy savings over the year, translating into lower operating costs.
• Lower maintenance workload and improved worker safety.
• Enhanced product quality and stronger brand reputation.

These results confirm that investing in high‑performance insulation not only protects product integrity but also delivers tangible ROI.

Zotefoams plc
675 Mitcham Road
Croydon, Surrey
CR9 3AL, United Kingdom
t +44 (0) 20 8664 1600
e [email protected]