Customized Solution:

• 3D modeling used to facilitate an aggressive construction schedule, and to coordinate the complex mechanical and electrical system installation.
• Waste heat from the chillers, hydraulic power unit and air compressors was utilized in the heat pump units to provide heating and cooling of the offices, data and server rooms as well as heat for the snow melt and in-floor hydronic heating systems.
• A geothermal pond loop system provided cooling for excess heat to minimize need for the cooling towers.
• Refrigeration systems were designed for future expansion to triple plant capacity in two additional phases of construction.
• The new facility included a refrigerated bulk storage warehouse, three processing lines, packaging, a refrigerated shipping warehouse, office and a test kitchen.
• Major equipment supplied includes four food-grade air handling units, five heat-pump roof-top units, four fan-coil heat-pumps, twelve ceiling hung evaporators, one packaged roof-top unit, two chillers, two ice-makers, cooling tower, pumps, variable area volume boxes, fan coil units, and exhaust fans.

Customized Solution:

• Rohde used 3D building information and shop prefabrication to the fullest extent possible in order to reduce field manpower requirements, increase the speed of project delivery, and to ensure space was allocated to fit everything required by all contractors including plumbing and electrical contractors
• Allen-Bradley programmable logic control system was employed at the facility to continuously monitor and control the entire system to ensure safe and energy efficient operation
• Rohde fabricated a variety of system components in our shop including ductwork, piping, and control panels
• Rohde built subassemblies as large as practical considering trucking and material handling requirements. Building components before space on site was available helped us maintain the demanding project schedule
• Rohde installed all components for the freezer including:

Customized Solution:

Design and installation of a 70,000 square foot in-slab snow melt system for the entire parking structure, including the parking deck, drives, sidewalks, stairwells and ramps. It included 25 zones and over 22 miles of buried PEX tubing.

Furnish and install steam to hot water heat exchangers, pumps, hydronic equipment, hot water piping in-slab tubing and controls for the entire snow melt system.

Major equipment supplied included a 3-stage high pressure steam reducing station, two steam to hot water heat exchangers, hot water pumps, expansion tank, glycol fill system and snow melt controls.

Addition and modification of storm water drainge for the parking deck.

Replacement of parking structure ventilation equipment with new fans along with controls to maintain ventilation rate to prevent carbon monoxide buildup.

Customized Solution:

• A custom designed heat pump that is 8 times larger than what is traditionally available

• Directly recovering heat from an ammonia refrigeration system

• Integration of hot water heating system controls with the ammonia refrigeration controls

• Remote monitoring and data collection

• Rohde designed, engineered and implemented the system within 6 months, typically during scheduled plant shutdowns. Working closely with Gold’n Plump’s team, Rohde ensured integration of the new system with minimal disturbance to the existing facility and processes in place

• Rohde engineers scaled an existing heat recovery design to accommodate the plant’s daily use of 1,000,000 gallons of 140°F water for production and sanitation

• This is the largest heat pump heat recovery unit in Wisconsin

• Saved Gold’n Plump $178,000 per year in energy costs