50kW Food Cooling Chiller

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Case studie 50kW Food Cooling Chiller

The Challenge

A prominent UK food manufacturer specialising in high-end prepared soups and sauces faced a critical operational crisis. Following a significant increase in contract volume, their existing cooling plant reached full duty. The facility was struggling to bring large batches of product from boiling temperatures down to a safe 4°C within the strict windows mandated by food safety legislation.

The inconsistency of their legacy equipment created a “domino effect” of inefficiency: production cycles were stalled, energy bills were skyrocketing due to overworked compressors, and the risk of bacterial growth was becoming a genuine concern for the quality control team. They required a robust, reliable 50kW Food Cooling Chiller that could handle intense production demand.

They didn’t just need a machine; they needed a partner who understood that in food production, a single degree of temperature variance can result in thousands of pounds in wasted stock.

The Survey

Rapid Chillers dispatched a senior industrial engineer to perform an immediate survey. Unlike standard providers, we analysed the specific flow rates of their process, using the delta t to calculate the peak cooling loads during their most demanding production , factoring in potential air temperatures for the time of year.

Our survey identified that the existing pipework was undersized for the required volume, leading to pressure drops that throttled the cooling process. We also discovered that the ambient heat within the production hall was significantly impacting the efficiency of the glycol cooling units. By taking these granular measurements, we were able to guarantee a solution that wasn’t just “off the shelf,” but precision-engineered for their specific food production efficiency goals.

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The Solution

We recommended and installed a bespoke 50kW Food Cooling Chiller, built to a rigorous industrial specification. Knowing that reliability is the cornerstone of trust in the B2B sector, we equipped the unit with redundant scroll compressors to ensure that even during routine maintenance, the cooling process never stops.

The solution featured:

  • Precision Temperature Control: Advanced PLC integration allowing for set-point accuracy within $\pm 0.1°C$.
  • Food-Grade Construction: Stainless steel internal components and a non-toxic glycol circuit to ensure total hygiene compliance.
  • Intelligent VSD Pumps: Variable Speed Drives that automatically scale power up or down based on the batch load, drastically improving the [link to: food cooling systems] efficiency.
  • Remote Monitoring: A cloud-based dashboard allowing the facility manager to track performance in real-time, providing total peace of mind.
Case studie 50kW Food Cooling Chiller

The Result

The installation of the 50kW Food Cooling Chiller delivered immediate, measurable improvements to the client’s bottom line. By partnering with Rapid Chillers, the manufacturer achieved:

  • 18% Increase in Daily Output: Rapid pull-down times allowed the facility to add an extra production run every 24 hours.
  • 8% Reduction in Energy Consumption: The intelligent VSD technology prevented the “on/off” power spikes associated with their older [link to: industrial chiller].
  • 100% Regulatory Compliance: The precision cooling ensured all batches met FSA safety standards, eliminating product waste.
  • Enhanced System Longevity: By correctly sizing the unit to the load, the mechanical strain on the system was reduced, extending the projected lifespan of the plant by years.

Facing similar cooling challenges in your food production facility? Explore our full range of Cold Storage Hire or contact us to book a free on-site thermal survey with one of our applications engineers.

Case studie 50kW Food Cooling Chiller

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