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Founded in 1965, Craigavon-based, Avondale Foods is an innovative, award-winning fresh food manufacturer. The business supplies Ireland and the UK’s multiple retailers with a wide range of fresh products. As well as the fresh food manufacturing Avondale also has its own on-site bakery for the production of additional lines including croutons, doughballs and porridge.
Challenge
Reliable cooling temperatures in food production are critical and no one knows this better than one of Ireland’s leading food manufacturers and suppliers.
Facing the prospect of replacing an aged chiller and the financial outlay required, Avondale saw an opportunity to incorporate the advantages of modern technologies to boost efficiencies and drive down its carbon emissions. The business was also keen to maximise its investment, by future-proofing as much as possible to meet further increases in demand for its products.
There were also logistical hurdles to overcome. With a 24/7 business operation disruption had to be minimised. Any system selected had to offer the precise temperatures required as any fluctuations in temperature could spoil batches and waste money. The company’s chillers also run 70-80% capacity, but are switched off when they are not required, so timing was key.
Solution
Avondale worked closely with Aermec, Powertech Refrigeration and Falkonair UK, specialists in energy efficient systems and solutions to achieve the desired energy efficient HVAC-R solution.
The brief required a chiller could offer scope for increased capacities, deliver lower running costs, lower noise levels, react to changes in product loads and quickly and offer an attractive ROI.
Aermec’s NRB0800Y high efficiency air-cooled chiller was selected. To release additional energy savings a smart compressor control using Variable Speed Drives (VSDs) was used to enable the compressors to operate smarter, achieve greater efficiencies and generate greater cost savings. VSDs were integrated on both the refrigeration circuits, and this reduced the chiller’s energy consumption further, even when running continuously at high loads. The VSD’s enable modulation of the scroll compressors operation in Aermec’s air-cooled chiller.
Some modifications were carried out; to minimise cooling interruption the chiller was designed to include a fast re-start within three minutes, thus reducing the risks of expensive downtime and ensuring fast delivery of chilled water at the desired temperature.
Logistical challenges were overcome by craning the chiller into position and constructing custom-built steel frames for mounting the chiller on. To avoid any disruption to production the installation and commissioning also took place at specific times in the evening. Pipework and connections were carried out in advance.
Result
Avondale uses Aermec’s air cooled chiller to cool water down to 0⁰C and then circulates the water in a chilled water loop through a heat exchanger which provides chilled water for food processing. The unit has a nominal cooling capacity of 129. 7kW.The chiller provides a reliable supply of cool water for the cold-water tanks within an acceptable tolerance and the heat exchanger provides cooling for the soups and coleslaws.
An independent assessor confirmed the energy savings. The chiller’s four compressors were rated at a nominal electrical consumption of 30kW. Data acquired showed that the chiller was on standby 46% of the time, ran one or two compressors for 27% of the time and only used three of the four compressors for 6% of the time. During standby the chiller cycled in and out to maintain the required temperatures. The chiller showed a reduction in electrical consumption of 41% which was largely as a result of the VSD drives.
Avondale now benefits from a cooling solution that delivers the required energy saving benefits and is better placed to cope with any future growth. Its PPM strategy will ensure the cooling system will continue to perform optimally, delivering efficiencies whilst reducing emissions, and offering an attractive ROI.
High efficiency air-cooled chillersSmart compressor technologyFast re-start within three minutesAchieved 41% reduction in energy usage
Being a significant player in the European air conditioning market for over 60 years, we are dedicated to the development and testing of our products and the value they bring to our customers. Not just at install, but the lifetime value of an Aermec installation. We believe in the importance of continual research and development, with particular emphasis on rigorous testing of every chiller and heat pump after its assembly, before it is dispatched.
Registered in England Company No. 3112873
