Efficient solutions for fresh produce cooling

When Lindsay Fresh Logistics approached Bruce Townsend, a Director of Cool Dynamics (QLD), about updating their primary distribution warehouse at the Brisbane Markets, he got Bitzer involved.

Lindsay Fresh Logistics needed to update their refrigeration at the Brisbane Markets to handle increased product throughput, different operating conditions and deliver improved operating efficiency.

The Brisbane Markets site had performed reliably over the last twenty years using Bitzer open drive screw racks, Buffalo Trident LDV condensers and Thermfresh air handlers, however this system no longer suited the proposed operating requirements. It also utilised an operating charge in excess of 2,000kg of R22, contained in just three systems, and was going to become dramatically more expensive to keep operational in the future.

As the site needed to keep operating while the plant was upgraded, the idea of swapping the open drive screw racks with semi hermetic screw racks with the central plant operating on R134a was eventually dismissed.

Thinking outside of the box and following on-site discussions between Lindsay Fresh Logistics, Cool Dynamics (QLD) and Bitzer, it was decided that each room would have its own dedicated small charge system which would allow for the other rooms to continue operating on the existing plant as each new system was installed and commissioned.

For efficiency the site went with four Bitzer Commech screw sets, two semi hermetic racks with Varispeed lead compressors, two Varispeed basic units, and a semi-hermetic basic unit.

All were selected to operate on R134a and combined with Buffalo FMC condensers featuring EC fans. These were mounted remotely on a condenser platform engineered and installed by SBP Australia on the warehouse roof and designed to ensure optimal condensing temperatures could be easily maintained regardless of ambient temperature.

New Buffalo BBM series evaporators, which are designed for optimal humidity and air flow, replaced the existing Thermfresh air handlers. All of the Bitzer compressor sets were supplied pre-wired with Carel control systems which were then connected via BACnet to a custom Innotech BMS system to allow for remote communication.

The project was completed over six months with the majority of the work, including the infilled cool room panel by SBP Australia, completed in November.

Lindsay Fresh Logistics were pleased to share their first power bill for December with Cool Dynamics (QLD). It revealed a 29 per cent power saving compared to the previous December period.

As the last of the new equipment was commissioned and the old plant decommissioned the power savings continued to improve. March showed a 37 per cent decrease from the previous corresponding period even with building additions of

three fumigation rooms, one DAF (Department of Agriculture & Fisheries) conditioned facility and three fast cooler rooms.

In February there was a slight anomaly (with temperatures an average of three degrees warmer than in February 2015), so power saving dropped from 37 per cent to 22 per cent, however the new equipment cruised through the heat providing optimal COP efficiency.

“The equipment changeover
took place with minimal disruption to our operation due to the
great communication from Cool Dynamics (QLD) during all stages
of this project,” said Bob McMillan, General Manager of Rocklea Markets site.

“This allowed us to plan for the shutdown of rooms based on product flow so that Cool Dynamics (QLD) could ensure that they had the rooms we needed operating when we required them.

“We have since noticed a considerable drop off in power consumption even though we have added rooms, plus our water consumption would have also decreased with the removal of the Thermfresh units.”

Lindsay Transport Adelaide refrigeration upgrade was also very successful and 2016 is looking to
be a great year for Lindsay Fresh Logistics, in the Brisbane Markets, with the additional cold storage to handle their export market growth, plus an estimated average 32 per cent power saving and continued to be fully supported by Cool Dynamics (QLD) and Bitzer Australia.



Small Cabinet Coolers

Exair’s new small 316 Stainless Steel Cabinet Cooler Systems keep electrical enclosures cool with -7°C air while resisting heat and corrosion that could adversely affect the internal components. The wear, corrosion and oxidation resistance of Type 316 stainless steel encourages long life and maintenance free operation. Cooling capacities up to 550 Btu/hr are ideal for small electrical enclosures and heat loads. Models with higher cooling capacities up to 5600 Btu/hr for NEMA 12, 4 and 4X enclosures are also available.

The Cabinet Coolers circulate -7°C air throughout the enclosure to prevent high temperature malfunctions. They mount through a standard electrical knockout while maintaining the NEMA 12, 4 or 4X rating of the enclosure. Cabinet Cooler Systems include an automatic drain filter separator to ensure no moisture passes to the inside of the electrical enclosure. An optional thermostat control minimises compressed air use and keeps the enclosure at within 1ºC of the temperature setting. A side mount kit is available when space restrictions prevent mounting on the cabinet top.

Small 316 Stainless Steel Cabinet Coolers are available with cooling capacities of 275 and 550 Btu/hr and are UL Listed and CE compliant. There are no moving parts to wear out. Applications include cooling control panels used in food processing, pharmaceuticals, foundries, chemical processing and other corrosive locations.

New refrigeration technology for enahnced food safety

When it comes to maintain the highest levels of food safety, consistent and reliable refrigeration is a big part of the equation. 

At its 2015 Technical Roadshow, global refrigeration innovators Bitzer presented a new combination cooling system that caused quite a stir. Hailed as revolutionary and hungrily accepted by the industry, Bitzer’s new combination of the Evolution air-cooled condensing unit, plus PS Series evaporator with EVD-ice electronic valve driver boasts a three-months return on investment. 

Available fitted to the Buffalo Trident PS Series evaporator, the recently launched EVD-ice is the evolution of Carel’s electronic valve driver specifically designed to operate under extreme conditions, such as within the evaporator in a cold room. The EVD-ice can be easily connected to a supervisory system for external monitoring of operating conditions.

With the addition of Carel’s Ultracella technology, the user doesn’t even need to be in the cold room – messages, alarms and status display are all accessible from outside the room. 

Plus, the Ultracap module is an additional option for users needing an IP65 rated solution, with over-molding completely sealing the device. 

The short pull-down times and system performance result in improved food quality and in turn further cost and efficiency savings for food manufacturers. 

Huge fans for food & beverage makers

Big Ass Fans has launched Essence, a new fan in Australia that’s a bit different from the traditional, enormous industrial fans the company is named for. 

Ranging from 2.4 to 4.2m in diameter, the fans are designed to provide quiet, comforting air movement more suitable for commercial spaces such as food/beverage areas, offices and lobbies, and sound-sensitive environments. 

When designing the new fan, the company said its engineers started by identifying shortcomings of existing fans and then replaced the traditional, geared ceiling fan motor with a maintenance-free, permanent magnet drive. 

The motor features multiple microprocessors that monitor room conditions, like temperature power use and so on, in order to ensure lasting performance.
In air conditioned spaces, the fan’s breeze is said to reduce reliance on expensive, energy-intensive air conditioning. In the summer, the fan’s breeze can create up to a 5.5°C cooling effect, so building managers can raise thermostat setpoints to reduce air conditioning usage by up to 30 per cent.

During colder months, the fan can be slowed to gently push warm air trapped at the ceiling down to occupant level, lowering heater usage. Additionally, the fan is damp rated so it can be used indoors or out, serving as an energy-efficient alternative in spaces where air conditioning is impractical.