Optimization of pressure in the cooling system

In the food plant, we optimized the cooling system, reducing energy consumption by 800 MWh/year and CO₂ emissions by 640 tons. The modernization increased compressor efficiency and generated savings of up to 600,000 PLN annually.

The challenge

In food industry plants, cooling and freezing processes of products generate very high energy consumption.

In the analyzed plant, storage chambers required an evaporation temperature of -27^oC, while compressors were set to operate at a much lower temperature of -42^oC. This caused unnecessary energy losses and reduced the efficiency of the entire cooling system.

Our approach

DB Energy experts conducted a detailed analysis of the cooling system, including:

measurements of actual energy consumption by the compressor system under different operating conditions,
analysis of the temperature profile of storage chambers and freezing tunnels,
comparison of operating parameters (set evaporation temperature -42^oC vs. technologically required -27^oC),
assessment of compressor efficiency at different evaporation pressure levels,
modeling of control scenarios – gradual cooling to the target temperature and introduction of an intermediate stage at -37^oC,
verification of the impact of changes on product quality and storage process stability.

Based on this, it was identified that the main cause of excessive energy consumption was the unjustified maintenance of the evaporation temperature well below technological requirements. The proposed approach considered both energy loss reduction and the quality safety of the freezing process – a key factor in the food industry.

Solution

We proposed:

introduction of an intermediate cooling stage of the refrigerant to -37^oC,
modernization of the compressor control system,
extension and precise control of the product dwell time in the freezing tunnel.

This optimized the process of reaching the target temperature in storage chambers while maintaining the required food quality and safety.

Results

The actions taken resulted in:

energy consumption reduction: approx. 800 MWh/year
estimated cost savings: ~500–600 thousand PLN/year (at energy prices of 600–750 PLN/MWh)
CO₂ emissions reduction: ~640 tons/year
payback period of investment: < 7 years
increased control over the freezing process and system stability

Pressure optimization in the cooling system - results

Conclusions

Modernization of cooling systems in the food industry is an area with very high energy efficiency potential. Precise adjustment of system operating temperatures to actual technological needs allows reducing energy consumption, improving freezing quality, and significantly lowering costs. Optimizing compressor operating parameters is an example of an investment with a relatively simple character but a significant impact on the plant’s energy and emissions balance.

Nasze najnowsze realizacje, które Cię zainteresują

The largest LNG-powered cogeneration unit in southern Poland – Schumacher Packaging Myszków

The largest LNG-powered cogeneration unit in southern Poland is now operating at Schumacher Packaging in Myszków. Thanks to an investment of 21.8 million PLN, the facility has achieved nearly 80% energy independence, producing almost 9 MW of electricity and significant amounts of heat. The project, implemented by DB Energy, demonstrates how an energy audit can serve as a starting point for a comprehensive energy transformation of a factory – from modernization of existing heat sources, through energy recovery, to the implementation of advanced cogeneration.

Przejdź do artykułu

Higher production and lower emissions – a chemical industry client on the path to net zero

At a chemical plant in southern China, we developed a 4-month strategy to reduce emissions by 70%, enabling increased production while lowering energy consumption and laying the groundwork for achieving net zero by 2035.

Przejdź do artykułu

Zero-emission in practice – emission reduction in pharmaceutical chemistry

Zero-emission in the chemical industry is not theory but concrete action. For a client in the pharmaceutical sector, we prepared a CO₂ reduction roadmap and implemented an incinerator modernization with heat recovery. The result? 12 GWh of thermal energy saved, a reduction of 2,172 tCO₂, and a quick payback period.

Przejdź do artykułu