Lion dairy and drinks has undertaken a $2 million chiller upgrade replacing its r22 system with ammonia.
The food and beverage company replaced two 800kW Mycom R22 screw compressors with two 1400 kW GEA ammonia screw compressor packages.
Designed by consultancy Beca Pty Ltd, the upgrade was undertaken by Gordon Brothers Industries who were able to integrate the existing 900kW Mycom ammonia screw compressor into the new system.
The project involved the replacement of existing cooling water pumps, primary glycol pumps and secondary glycol pumps, the glycol storage tank and integration of the existing BAC cooling towers into the new system.
As will as improved redundancy, the upgrade has increased glycol storage capacity from 10,000L to 36,000L.
The project has also increased turndown and energy efficiency with the inclusion of Variable Speed Drives on the new chillers and pumps.
Project engineer, Chris Enno, said the biggest challenge was minimising downtime for Lion’s dairy food production.
He said the main changeover from the existing system to the new system was completed within a five day shutdown.
“The new equipment was designed so that it could be installed in stages while the existing plant was still running reducing the works required during the five day shutdown,” he said.
“Limited space within the existing plant room required detailed design attention as well to ensure the new equipment could fit while still maintaining space for access and service.”
Enno said GEA chillers were selected because of compact design, high performance, low ammonia charge and quick delivery.
GEA sales manager, Greg Clements, said the chillers were broken down and freighted as six individual components per chiller to assist with space challenges within the existing plant room.
Lion employs 7,500 staff in Australia and New Zealand.