At Rohde Brothers, we recently completed a challenging yet rewarding project for Grande Cheese – redesigning and implementing an expanded ammonia refrigeration system in just 7 ½ months. This project is a testament to our ability to deliver efficient, cost-effective solutions under tight timeframes.

Project Overview: The task was to expand the existing ammonia refrigeration system while integrating advanced controls and maximizing the use of the existing infrastructure. Our team not only met but exceeded these requirements through innovative engineering and design.

Our Customized Solution:

1. Efficient Design: We significantly reduced the ammonia charge in the system from 14,000 lbs to 7,000 lbs. This was achieved by eliminating the high-pressure receiver, a key aspect of our redesign.
2. Advanced Technology Integration: We incorporated variable frequency drives on all components, including two new 150 HP compressors.
3. Optimized for Seasonal Efficiency: The system was designed to operate at lower pressures during cooler months, enhancing efficiency and reducing costs.
4. Redesign of Expansion Devices: Our redesign ensured that high pressure liquid wasn’t necessary for the evaporator coils, improving system safety and efficiency.
5. Maintenance and Safety Improvements: By removing surge drums, we eliminated the need for frequent relief valve changes and simplified oil drainage in the ammonia room.
6. Significant Cost Savings: The project resulted in over 38% savings in electrical costs and reduced gas costs by 5-10%. Maintenance and operating costs were also significantly lowered.
7. Compliance and Additional Savings: Our redesign brought the system below EPA and OSHA thresholds, eliminating the need for a full Process Safety Management program and saving $30,000 in consulting fees.

Client Impact: Grande Cheese benefited greatly from our solution, not only in terms of system efficiency and safety but also through substantial cost reductions. The project’s success reflects our commitment to providing high-value, sustainable solutions to our clients.

Conclusion: This project with Grande Cheese showcases Rohde Brothers’ expertise in industrial refrigeration systems. We pride ourselves on delivering customized, efficient solutions that meet specific client needs while ensuring environmental and safety compliance. If you’re looking for a partner to upgrade or redesign your refrigeration system, Rohde Brothers is here to bring your project to life.

Since the early 1970s, Rohde Brothers has been a key partner in Johnsonville Sausage’s journey of growth and innovation. Our longstanding collaboration has spanned various projects, big and small, across their multi-plant meat processing campus.

Long-Term Partnership: Our relationship with Johnsonville Sausage’s engineering department is built on mutual trust and a deep understanding of their needs. We’ve been involved in everything from minor HVAC system adjustments to major installations and maintenance projects in process and wastewater treatment plants.

Highlight Project – The Meadowside Plant Expansion: A standout example of our collaboration is the Meadowside Plant Expansion. Here, we successfully completed the HVAC work for the 81,600 square foot expansion. This project included:

1. Customized Ventilation Solutions: We designed and installed ventilation systems tailored for new custom cook equipment.
2. Controls and Steam Piping: Our team expertly handled the installation of control systems and steam piping.
3. Efficient Execution: Despite tight deadlines and the need to avoid disrupting ongoing operations, we delivered on time and beyond expectations.

Client Testimonial: Eric Grams, Senior Project Manager at Miron Construction Co., Inc., praises Rohde Brothers for our deep industry knowledge, ability to understand client needs, and proficiency in execution, leading to repeated collaborations on Johnsonville Sausage expansion projects.

Our Customized Solutions: Our work encompassed a variety of complex tasks, including:

• Engineering and application problem-solving with effective trade coordination.
• Unique solutions for process ventilation, steam, and gas service.
• Installation of advanced HVAC systems, including controls and high-pressure steam piping.
• Specialized ductwork in food production areas using heli-arc welded stainless steel.

Conclusion: At Rohde Brothers, our commitment to innovation and efficiency shines through in projects like the Johnsonville Sausage expansions. We take pride in delivering tailored solutions that meet and exceed our clients’ expectations. If your business seeks a partner for advanced industrial solutions, Rohde Brothers is ready to bring value and ingenuity to your projects.