General Refrigeration installed a new chilled water system at this poultry company. The system includes 3 screw compressors, 4 evaporative condensers, 2 falling film plate chillers, 2 shell & tube red water chillers, 5 process chillers, 3 large 25,000 gallon chilled water storage tanks, and a complete computerized control system. Additional product cooling is also available by icemakers that were installed previously to an adjacent system. These systems can run during off-peak hours and store ice and chilled water that can be used in the future; this creates savings in electricity cost. It also allows for a total backup of cooling if the chilled water in the plant must be drained for inspection reasons. The total tons of refrigeration exceed 1300 TR. Not only is this system dependable and efficient, but it can also be controlled remotely by the computer system that monitors all set points, levels, temperatures, and pressures.

This large poultry processing plant has undergone major construction that has approximately doubled its square footage. The existing refrigeration system was upgraded and additional equipment was installed to increase the capacity. The new equipment included 7 ACUair hygienic roof top air handlers. These ACUair units incorporate state-of-the-art technology to provide refrigeration, pressurization, condensation control, and sanitation needs required in the food processing industry. They use 2 stages of filters (HEPA) and operate at positive pressure to keep any contaminants from entering the room. During cleanup the unit switches to a heating mode to absorb the humidity that is created from the sanitation procedure. A dampering system, used during cleanup, pulls fresh outside air into the room and forces all of the wet hot air outside.

The refrigeration system is complete with a computerized control system that monitors every aspect of refrigeration at the plant. Trending and data recording are automatically saved to assist in any operational questions or trouble-shooting.

General Refrigeration installed a new stainless steel icemaker to provide direct contact product cooling. This icemaker was connected to the existing ammonia refrigeration system. An additional screw compressor and evaporative condenser were also added to provide a needed capacity increase.

Many food processing plants require ice to maintain needed product temperatures. Most icemakers are constructed of carbon steel, which will rust and flake in a consistently wet and cold environment. This can create a major USDA problem if any of the rust falls into the ice. Some plants have had to shut down and empty their entire ice storage because rust from an icemaker had contaminated the ice. We have developed a stainless steel icemaker (GR Stainless Ice) that will never rust or flake. This icemaker was custom designed for this plant and can develop over 50 tons of ice a day.

This poultry company has installed an ammonia refrigeration system that contains 3 blast tunnels that use chain driven trolleys to automatically move the product. The system also includes 4 Frick screw compressors, 1 evaporative condenser, 1 thermosyphon/receiver vessel, 1 ammonia recirculator package, and an automatic purger.

Energy, time, and storage space can be very expensive. This is why many companies have turned to blast tunnel systems. These systems bring the temperature of the product down very quickly and allow the product to be shipped to the customer instead of sitting in a large cooler room. This saves energy and square footage because a large cooler room is not needed. In addition, the product arrives at the supermarket quickly which enhances freshness for the end-user.

General Refrigeration retrofitted the high-pressure side of this processing plant's refrigeration system. All the discharge, condenser drain, and foul gas lines were replaced. The previous piping had been modified several times and had created traps and other piping problems. Some condensers were removed, and one large double-sided condenser was installed. The plant now consistently has low head pressure which has increased the compressor capacity and reduced the energy use.