Delivering Precision Cooling with Energy Efficiency Through Smart Integration

Challenge

A major food manufacturer required a new 3MW Cooling System to support critical manufacturing processes. The existing infrastructure presented several constraints that needed careful consideration. The solution required integration with an existing Ammonia Surge Drum package to optimise costs and energy consumption while maintaining precise temperature control for manufacturing operations.
The system needed to be installed in a live manufacturing environment with minimal disruption to ongoing production. Additionally, the project demanded full CDM compliance, comprehensive safety protocols, and seamless integration with the client’s existing Siemens PLC and monitoring systems.

Approach

Integral Cooling Tech designed and installed a comprehensive 3MW Cooling Pods System featuring a new glycol ring main with dedicated header connection points. The engineering solution leveraged the existing Ammonia Surge Drum package, utilising existing liquid pumps and level control systems to reduce capital expenditure and ongoing energy consumption.

The system operates with liquid Ammonia at a saturated temperature of -9°C circulated through plate heat exchangers, reducing glycol circuit temperature from -1°C to -7°C. The chilled glycol is distributed via the ring main to manufacturing loads, returning at -1°C for continuous circulation.

Located externally on the roof, three glycol pumps were mounted on a specifically designed and manufactured pump/PHE skid. The pumps operate in a duty/duty/standby configuration with individual variable speed drives for optimal control. The skid was fabricated off-site and assembled on-site within two days using a 450-tonne crane, minimising disruption to operations.

The project was executed under full CDM conditions with comprehensive HAZOP analysis, Design Risk Assessment, and Construction Phase Plan. A dedicated, non-working Site Manager oversaw all permits, daily activities, and health and safety protocols.

Results

The project achieved exceptional safety and operational outcomes. Both internal and external audits resulted in 100% safety scores for on site activities, documentation, and document control procedures.

The new cooling system successfully delivered precise temperature control for the client’s manufacturing processes while reducing energy consumption through integration with existing infrastructure. The rapid installation timeframe minimised operational disruption, and the modular pump configuration ensures reliable operation with built in redundancy. The system integration with existing monitoring platforms provides the client with seamless operational oversight and control, supporting efficient long term facility management.