1. Analyse
Compressor electricity, ice-water temperatures and flow data were analysed to evaluate overall refrigeration system performance.
Efficiency in refrigeration systems
When meeting cooling requirements masks inefficiency
Customer scenario
A dairy manufacturing site depended on nine ammonia compressors and an ice-water distribution network to deliver the cooling required by production. Although the system continued to meet production needs, this did not indicate whether it was delivering the required cooling efficiently or how much energy was being used to do so. By looking beyond the production outcome, the site could identify hidden inefficiencies that were increasing electricity consumption and operating costs.
What our energy experts revealed
Engineering insights led to targeted action
Cotopaxi's energy experts identified an opportunity to improve ice-water loop control, addressing how cooling was distributed rather than changing how it was generated.
Instability in the ice-water loop was limiting efficiency
Ice-water supply temperatures were inconsistent and regularly above the 1C setpoint. This indicated that tighter loop control could reduce the energy required to deliver the same cooling requirement.
Operational data revealed a hidden opportunity
Analysis of compressor electricity consumption, ice-water temperatures and flow data showed the system was using more energy than necessary to deliver the required cooling conditions.
From insight to action
2. Interpret
Engineering analysis associated the unstable loop conditions with lower system efficiency, revealing a hidden improvement opportunity.
3. Improve
Pump control was refined and existing VFDs were used to stabilise pressure and temperature throughout the ice-water loop.
4. Achieve
The system now delivers the same cooling requirement while using significantly less energy.
Why hidden inefficiencies matter
Meeting production targets is often mistaken for operating efficiently. In reality, industrial systems can continue delivering the required outcome while quietly consuming more energy, water and utilities than necessary. Because nothing appears to be wrong, these inefficiencies become part of normal operation. Even in well-functioning systems, opportunities often exist to achieve the same outcome with fewer resources. Combining operational data with engineering expertise helps expose these hidden performance gaps and achive improvement opportunities.
What hidden inefficiencies exist within your utility systems?
Talk to our energy experts to learn how operational data and engineering analysis can uncover opportunities that remain invisible during normal operation.
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