The Client –
UK leading chocolate manufacturer
The Challenge –
Legacy chiller system replacement
The Solution –
CO2 chiller system
Popular the word over, chocolate is a favourite indulgence, and the UK is one of the leading chocolate consuming countries in Europe. Chocolate features heavily within our popular culture and is often the go to gift when celebrating seasonal events such as Easter and Christmas.
A long-standing Aqua client, partnered with us for their temperature control requirements. They’ve invested and grown substantially over the years and now sit as one of the UK’s leading co-manufacturer of chocolate, working with most of the major brand names.
Situation
Our client produces a staggering 20,000+ tonnes of chocolate product every year, including Easter Eggs and Advent Calendars. With plans for further growth, they wanted to review their legacy cooling equipment and purchase a new system which would safeguard them against production downtime whilst future proofing their manufacturing facility for years to come.
The factory had two existing chilled water systems which were key to the chocolate manufacturing process. One provided chilled water for processes and room cooling, whereas the second circulated water at a much lower temperature, nearer to -30°C.
This colder line supplied cooling to several custom designed machines which are instrumental to the chocolate tempering process. Precise temperature control is critical here, otherwise the quality and consistency of the finished chocolate product can be negatively impacted.
Around fifteen years ago, 2 x 30kW chillers had been installed on a duty assist basis. But, as the chillers aged, and the business grew, unless both were running the plant struggled for cooling capacity.
Solution
Aqua designed, supplied and installed a new system based around an 80kW CO2 chiller. This chiller would be able to takes the full demand of both lines, as well as providing reserve capacity for future expansion.
A CO2 chiller could be considered because of the low application temperatures involved. An added benefit with CO2 is that it is a completely natural, non-flammable refrigerant. Commonly referred to as R744, the refrigerant has excellent properties with a global warming potential (GWP) of <1. This makes it an environmentally friendly option and it also protected the client against future refrigerant legislation around F-Gases.
To ensure the new system is ultra resilient and reliable, additional back up controllers and other features were incorporated into the final chiller design.
Results
“This project was so well suited to a CO2 chiller” said Aqua Sales Manager, Mark Whittaker. “It gives our client everything they’ll need from a cooling perspective and there’s plenty of room for growth built in. Reliability is so important within the confectionary sector, and we’ve spec’d this unit incredibly well to ensure it can stand up to another 15 years of chocolate production!”
Aqua will also support with the ongoing maintenance of their chiller going forward.
For help with your next CO2 chiller requirement, call the team on 0330 818 7969 or email sales@aquacooling.co.uk
Find out how we’ve supported food manufacturers with their temperature control needs.
