Roof Heating for Walkers Crisps Factory

The Goal

At the Walkers Crisps factory in Leicester, the world’s largest crisp production site, maintaining continuous operation is essential. The facility processes tons of potatoes daily and runs 24 hours a day, 365 days a year.

During winter, heavy snow on the roof directly above the production ovens risked overloading the structure and disrupting production. Scraptoft Electrical Services (SES) approached Heatmat (part of the Heatcom Group) to design a durable and efficient roof heating system that would eliminate snow build-up and safeguard the facility’s operations.

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Our Solution

Through our subsidiary Heatmat, Heatcom Group carried out a detailed on-site survey and produced a complete heating specification in collaboration with SES Electrical.

The roof heating system was divided into 11 independent zones, designed using CAD plans for precision. It consisted of 7 mm exterior heating cables manufactured in Denmark and installed with roof fixing strips and weatherproof adhesive to ensure long-term durability in extreme weather.

Each zone was controlled independently via five separate control systems equipped with temperature and moisture sensors for automatic activation. These intelligent controllers switch the heating on only when snow or ice is detected and off again once clear — maximising energy efficiency while ensuring reliable performance.

Two additional roof sections housing air-conditioning ducts and extractors were also fitted with heating to prevent snow damage. All materials were carefully tested with the site’s Kemperol triple-layer roof surface to ensure compatibility and safety.

The heating capacity ranged from 8.5 kW to 41.6 kW per zone, depending on the surface area — with outputs designed to handle severe snow loads.

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The Result

The installed system provides complete protection against snowdrifts and roof overloading, allowing Walkers Crisps to maintain full production capacity throughout winter without interruption.

The heating zones can be individually controlled depending on snowfall, giving the site maximum flexibility and minimal operating cost.

This project highlights Heatcom Group’s expertise, through Heatmat, in delivering large-scale, industrial-grade roof heating systems — engineered for reliability, safety, and round-the-clock operation.