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:
- 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.
- Advanced Technology Integration: We incorporated variable frequency drives on all components, including two new 150 HP compressors.
- Optimized for Seasonal Efficiency: The system was designed to operate at lower pressures during cooler months, enhancing efficiency and reducing costs.
- Redesign of Expansion Devices: Our redesign ensured that high pressure liquid wasn’t necessary for the evaporator coils, improving system safety and efficiency.
- 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.
- 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.
- 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.