Evaporative Condenser Replacement for Pukka Pies' Production Plant

The Challenge

Pukka Pies operated an aging ammonia refrigeration plant that, while maintaining relatively good overall condition, required strategic upgrades in critical areas. The evaporative condenser showed clear signs of wear and needed proactive replacement before equipment failure could impact their high volume production environment.

The challenge was to design and deliver a comprehensive upgrade solution while minimising disruption to Pukka Pies’ ongoing operations. As the project took place on an operational site, health and safety considerations were paramount to avoid downtime and safety incidents.

Solution

Integral Cooling Tech collaborated with leading manufacturers and highly skilled contractors to execute a comprehensive project plan that delivered exceptional results within an accelerated timeline. The project included:

• Complete replacement of the aging evaporative condenser with modern, reliable equipment
• Installation of Variable Speed Drives (VSDs) on fan motors for enhanced operational control
• Implementation of improved delivery pressure management systems
• Integration of optimised motor performance technology for smoother running conditions
• Comprehensive system upgrades designed to maximise energy efficiency and reduce operational costs

The works were meticulously scheduled in collaboration with Pukka Pies’ production team to ensure minimal impact on daily operations. Safety protocols were rigorously followed throughout, resulting in zero incidents during the project.

Result

The evaporative condenser replacement project was successfully completed and handed over in line with timeline expectations. Key outcomes included:

• Revitalised ammonia refrigeration plant with extended operational life spanning decades
• Enhanced system reliability ensuring consistent performance for high volume production demands
• Significant energy efficiency improvements through VSD technology implementation
• Superior operational control with improved equipment longevity
• Zero disruption to production activities during the entire project timeline
• Comprehensive system documentation and training provided to Pukka Pies’ engineering team, ensuring long term operational success