Ripening
Case study
IPL, part of the ASDA family, is one of the largest importers of produce in the UK.
IPL approached Cross Refrigeration, part of the Cross Group, to assist in this project which included replacing their existing Ammonia Refrigeration system with a new state of the chilled water/glycol system.
Background
In 2021 IPL expanding their existing production facility by approx. 200% from 150,000 square foot to 300,000 square foot of chilled distribution and packing including 18 No. 60 Pallet 3 Tier Banana Ripening Rooms. This also included a refurbishment of the existing chill store and production areas.
Challenge
Replacement of existing ammonia system which was nearly 30 years old, had reached its end of life and no longer energy efficient. Maintaining temperature in existing Chill stores while the new equipment was being installed on a live food site.
Capital and lifecycle costs were key drivers for IPL, in their decision for the new refrigeration system.
Solution
For the existing chill stores Cross proposed a Chilled Water/Glycol system using 3No. Rhoss Inverter Screw Chillers each 585kW @-2oC.
The Banana Ripening rooms and High Temperature Packing Areas were on a separate Chilled water system with no glycol using 2 No. Rhoss Scroll Chillers each 660kW @ 7oC.
Both pump sets for both systems are fitted with the latest Grundfos Inverter Pumps and all chill areas had all the old evaporators replaced with new cleanable spec evaporators with the latest electronic EC Fans.
Summary
IPL were able to continue to deliver excellent standards and quality products throughout the retrofit of the refrigeration system.
The sites energy usage was reduced considerably across all aspects of the Refrigeration Project.
We have now started a second phase of work that includes a further 24No. 60 Pallet 3 Tier Banana Ripening Rooms.
“IPL has undertaken a number of significant projects with the Cross Regrigeration over the last 3 years, including a full site re fridge (replacing a 25+ year old ammonia based system), and a large, two phase banana ripening installation. Cross group are experts in their field, and truly partnered with us to ensure we designed and delivered the optimum solutions. Project delivery was seamless; I often wondered when the work actually took place, as Cross simply got on with things in an unobtrusive way, with minimal impact to our ongoing operation. Cross were very competitive in their pricing, and again worked with us to ensure we could balance functionality and affordability. The cherry on the cake was the significant energy efficiency savings we have unlocked as a result of using state of the art, modern equipment, significantly reducing our energy usage, carbon footprint, and ultimately costs.”
