General Refrigeration Company performed a complete design-build of a 4,500 TR ammonia refrigeration system for a new Poultry Processing facility.  Our responsibilities included performing the initial load analysis, designing, installing and starting up the complete refrigeration and chilled water systems, coordination of control wiring and ductwork installation, and completing all required PSM and RMP paperwork.  The system used three (3) separate suction levels to handle the loads of the condensation control rooftop units, water chillers, rechillers, evaporators and ice maker.  Through our engineering design, project management, installation and startup services, we were able to provide a team to complete the project safely, on schedule and under budget.   

The driving force for this project was the need for a new processing area for a high-end fast food customer. A new cooler and shipping dock was installed and commissioned into operation during the first phase and then phase 2 consisted of converting an existing cooler and shipping dock to meet the buyer's requirements. 

General Refrigeration Company provided the necessary refrigeration system upgrades to accommodate the addition of approximately 17,000 square feet of processing area and 4,000 square feet of cooler space.  The expansion included two rechillers, ten inline chillers for parts chilling, sixteen evaporators, three compressors, one condenser, one vertical pump package, one suction accumulator, and the required ammonia detection and ventilation system upgrades.  Due to the layout of the facility, we had to find creative ways to fit the new equipment into tight spaces while still maintaining serviceability.

An incredible project landing in the $140 million range for the complete build, General Refrigeration Company was honored to be involved, providing the cross country piping system and the environmental control system for a new launch pad.

Through a collaboration with the end user, General Refrigeration Company was able to develop and execute a plan to reduce the ammonia charge at the facility by nearly 50%, while still maintaining the desired system performance.  Due to the overall success of the project, we are continuing steps to reduce the system ammonia charge in an effort to minimize their offsite impact as per the parameters set forth by the N.J.A.C. 7:31 Toxic Catastrophe Prevention Act Program Consolidated Rule Document.

General Refrigeration was tasked with upgrading an existing ammonia refrigeration and chilled water system to meet new production demands. A new compressor and chiller package were required to meet these requirements and without any additional floor space in the existing engine room, the challenge became finding a location to house the new equipment. At the same time, an existing mechanical room was scheduled to be reconfigured with some of the equipment due to be relocated out of the room. This project evolved into the mechanical room being completely gutted and then converted into a new engine room. General Refrigeration then installed the compressor and chiller package, associated ammonia and chilled water piping, and ventilation and ammonia detection system.