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Location: Leicester, UK
Project/Case: Walkers Crisps – Roof Heating System
Year: 2016
The Goal
At the Walkers Crisps factory in Leicester, the world’s largest crisp production site, 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. Therefore, Scraptoft Electrical Services (SES) approached Heatmat, part of the Heatcom Group, to design a durable and efficient industrial roof heating system. The system had to eliminate snow build-up and safeguard the facility’s operations.
Our Solution
Through its subsidiary Heatmat, Heatcom Group carried out a detailed on-site survey. The team then 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 used 7 mm exterior heating cables manufactured in Denmark. Installers fixed the cables with roof fixing strips and weatherproof adhesive to ensure long-term durability in extreme weather.
Five separate control systems managed the zones independently. Each control system uses temperature and moisture sensors for automatic activation. As a result, the controllers switch the heating on only when snow or ice is detected, and off again once clear. This maximises energy efficiency while ensuring reliable performance.
Two additional roof sections housing air-conditioning ducts and extractors also received heating to prevent snow damage. All materials were 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.
The Result
The installed system provides complete protection against snowdrifts and roof overloading. Because of this, Walkers Crisps can maintain full production capacity throughout winter without interruption.
The heating zones can be controlled individually depending on snowfall. This gives the site maximum flexibility and minimal operating cost. The 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.
Walkers-crisps.pdf
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