Delivering Energy Efficient Solution for Compleat Foods

Challenge

Compleat Foods faced critical system failures with their main site blast chillers nearing the end of their workable life. The existing system suffered from multiple leaks and breakdowns, and had been previously converted with refrigerant that was no longer available for top-ups. Additionally, the potable water system was prone to failure, creating a dual problem requiring urgent resolution. The solution needed to be implemented in a live bakery environment with minimal disruption to operations.

Approach

We collaborated with the site engineering team to develop an energy-efficient solution that addressed both failing systems simultaneously. We designed a new transcritical CO2 packaged unit capable of delivering 350KW of -4°C cooling to the blast chillers and 100KW of potable water using glycol as a secondary refrigerant. With a tight implementation timeline, we installed the new plant in parallel to the existing system, completing all mechanical and electrical installations needed for final connections. Over a single weekend, we decommissioned the existing plant, removed old evaporators from the factory, installed X4 new evaporators, pressure tested the system, and had the new equipment operational by Monday evening.

Results

The new natural refrigerant-based system successfully eliminated 4,300 tonnes of CO2 emissions to the atmosphere. The upgrade future-proofed the site’s operations while significantly reducing emergency breakdowns and repair and maintenance costs. By combining the blast chill and potable water systems into a single solution, we delivered improved reliability and energy efficiency for this critical food production facility with minimal operational disruption.