Excalibur improve refrigeration efficiency at Cargill by 30%
Part of Cargill since 2008, Freeman’s of Newent are a primary chicken processing business, supplying independent butchers and the retail food sector.
As part of Cargill’s drive to improve energy efficiency a site review showed that the spiral refrigeration plant used to cool chicken prior to packing and despatch was a major energy user.
The system comprises five large Sabroe reciprocating compressors, operating on the R22 replacement refrigerant R417a, which processes 72,000 chickens a day. Due to the site having a limited electrical supply power is provided from 2 oil fired generators.
Freeman’s approached Excalibur to investigate the possibilities of improving the efficiency of this system. A study was undertaken which enabled Excalibur to identify the potential to reduce energy consumption by more than 30%
Excalibur were contracted to undertake the modifications which involved the installation of Liquid Pressure Amplification and inverter control of condenser fans, the system was then recommissioned to operate at low head pressure, reducing compressor energy consumption and increasing refrigeration capacity.
The effects of the modification were immediate; production was increased due to lower temperatures in the chiller, while oil consumption of the generators dropped by 1000 litres / week. Achieving a payback against investment of 18 months, and an annual reduction in carbon emissions of 150 tonnes.
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