Case Studies

Expanding a Refrigeration System for a Global Beverage Producer

Increasing the Refrigeration Capacity of a Global Beverage Giant's Facility to Over 3.37 mWR (Without Production Disruption)

ADEAREST successfully expanded and relocated a refrigeration system for one of the largest global producers of beverages and carbonated drinks. This project increased cooling capacity and enhanced operational flexibility, all while ensuring uninterrupted production.

Project Overview

The project aimed to expand the existing refrigeration system by relocating equipment to a new plant room while maintaining production continuity. The system, originally designed to provide cooling at -2^oC, was upgraded with additional refrigeration equipment in the new plant room. The transition was carefully managed, gradually transferring the load to the new system before relocating the compressors.

Key Solutions

ADEAREST’s approach involved installing ammonia compressors with VFD motors, an evaporative condenser, and a hot & cold glycol buffer tank operating at +2^oC. The new pipelines extended glycol distribution across the factory, integrating with the RO water cooling system. The condenser setup was optimized by combining new and existing condensers to ensure efficient cooling through a shared high-pressure liquid receiver.

Key Technical Features

The refrigeration system included ammonia compressors with Variable Frequency Drives for energy-efficient load handling, an evaporative condenser to enhance cooling performance, and a glycol buffer tank to ensure steady temperature control. The precision cooling system allowed the temperature of RO water to reduce from +35^oC to +14.5^oC. This is crucial for high-quality beverage production. Additionally, new glycol pipelines were installed with insulation and aluminium cladding for process cooling.

The system features ASME-approved pressure vessels, ensuring safety and compliance with industry standards.

This setup is also equipped with a state-of-the-art PLC system, ensuring operational efficiency and system reliability.

Solving Challenges

A key challenge was relocating the existing equipment without interrupting production. ADEAREST meticulously planned the transition, shifting loads line by line onto the new system before relocating each component. The installation of the new pipelines and the welding and insulation of cold pipes were executed with precision, ensuring minimal impact on ongoing operations.