Cooling Milfos

Product Catalogue Central to the function of every dairy farm is the collection and storage of milk. Milk quality can only be guaranteed when the milk cooling process is efficient and reliable.

engineering for a better world

GEA Farm Technologies

T ICE AATES V R G SE ERS M FAR

CONS ULTA NC Y H

M SY ILK S I T EMNG S

RN ENT A B PM UI Q E

HYGIENE CONSULTANCY

EFFLUENT TECHNOLOGY

MA FA NA RM TO GE OL ME S

E & CTS EN DU GI RO HYTH P L EA

NT

ATIC TOM AU EEDING F

MILK STO R & C O OLIN AGE G

Overview GEA has developed market leading snap chilling and heat recovery systems called the aquaTESS & aquachill.

GEA also has two hygienic storage solutions available. Both offer excellent energy efficiency and cooling characteristics to meet the need of any installation.

Whether it is a standard solution for storage of milk or an integrated solution which takes in smart controls, an automated cleaning system, snap chilling and energy saving heat recovery, GEA has a solution to meet your cooling needs.

2 | Milk Chilling Brochure

Table of Contents Why Snap Chill Milk? ������������������������������������������ pg 5 Introducing aquaCHILL ��������������������������������������� pg 7 iCONVERTER Cooling & Heating Cell ������������������ pg 8 iCONVERTER & Thermal Energy Storage ������������� pg 9 The iCONVERTER range �������������������������������������� pg 10 iCOOL ����������������������������������������������������������������� pg 13 iSTORE ���������������������������������������������������������������� pg 14 Complete Turnkey Solution ��������������������������������� pg 15

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4 | Milk Chilling Brochure

Why Snap Chill Milk?

Naturally occurring bacteria in the milk starts multiplying straight away and only temperature can slow the process down to preserve milk quality.

Needless to say then, snap chilling milk has a number of fundamental benefits for both the milk producer and the processor.

High quality milk has a longer shelf life and can be processed into more high value products than raw milk that has higher levels of bacteria.

900 Million bacteria per ml

Milk starts to deteriorate the moment it is harvested from the cow.

20˚C

30˚C

500

15˚C

25˚C

10 3 1 0.3

4˚C 0

4

8

12

16

20

24

28

Hours after milking

Milk Quality Compliance (The Regulatory Issues) • Bactoscan (bacteria count, milk chilling related) • Thermoduric (heat resistant bacteria) • Coliforms (wet weather / manure bacteria) All of the above issues can be greatly improved by snap chilling and high grade heat recovery for maximum plant hygiene.

Key Features • Milk quality • Up to 37% Energy Savings • Factory compliance • Future proof your farm from pending changes in milk chilling standards

This graph clearly demonstrates why milk processors insist on milk being chilled to 4°C as quickly as possible at the end of milking.

The lower the milk temperature into the Bulk Milk Tank, the lower the bacteria or bacto count when the processor collects the milk.

Note: Below 10°C bacteria growth is seriously reduced and is practically stopped at 4°C.

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6 | Milk Chilling Brochure

SECOND MILK PHE

CHILLER EVAPORATOR

BUFFER TANK

GLYCOL CIRCULATION PUMP

Introducing aquaCHILL aquaCHILL is designed to help any farmer to meet cooling standards, ideal for a retrofit situation or a new install. aquaCHILL is a booster for your cooling system.

The advantages of aquaCHILL: • No thermal storage so only runs when you need it • Runs in tandem with existing vat chilling

Above: Diagram shows how the aquaCHILL system works.

• Hot water reclaim available • A simpler solution means lower prices • ‘Plug and Play’ solution (very little installation required) • Can be moved from farm to farm if required How does it work?

The aquaCHILL is a direct-on-line snap chilling system. What this means is that the power available for cooling at the Plate Heat Exchanger (PHE) is only what is produced by the chiller. The aquaCHILL only runs during milking.

The Glycol is circulated through the evaporator to the milk PHE and back to the buffer tank. The buffer tank provides a ‘thermal shock absorber’ and prevents compressor short cycling with milk pump switching.

What is included in the aquaCHILL package?

The aquaCHILL package is a ‘plug and play’ solution which requires minimal installation on site compared to any other snap chilling solution on the market.

All the required components are neatly assembled on a galvanized steel plinth and tested before delivery.

Components on the Plinth are: • Air-cooled water chiller with Ciat CONNECT2 controller • Lowara 210/5 circulating pump • Single bank Ecoflex NT50M 8000L Plate Heat Exchanger • 500L Buffer Tank The only installation required is diverting the milk line to the Plinth mounted PHE and running power to the chiller from the switchboard. In an ideal installation the chiller can be installed and running between milkings.

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S

2

ENERGY SAVING

3

MULTIPLE BULK MILK TANKS (BMT)

1 4

5

FREE HOT WATER GENERATION

THERMAL STORAGE

This diagram shows the basic relationship of each key aspect of the iCONVERTER installed in the average milking system.

SNAP C

HILLING

iCONVERTER Cooling & Heating Cell The iCONVERTER is an ‘All-in-One Cell’ designed specifically for on-farm milking, heating and cooling management.

The hybrid cell design is totally unique, delivering superior energy performance over all other solutions available on the market today. The iCONVERTER can typically reduce total energy consumption of the farm dairy by as much as 37%.

Key Benefits 1. Free Hot Water Generation

Coefficient of Performance (COP).

The iCONVERTER uses a new high pressure refrigerant called R410a.

This allows the system to generate free hot water at an average of 60°C, giving plenty of hot water for maximum plant hygiene. Spare hot water can be used for other uses such as re-heating calf milk, plant washing etc.

3. Multiple Bulk Milk Tanks (BMTs)

2. Energy Savings The iCONVERTER is classified as a ‘Class A’ efficiency refrigeration system.

This means it has been tested and certified to generate over 3kW/h of chilling output for every 1kW/h of electricity input. This is a ratio of at least 3:1. This ratio is often referred to as Energy Efficiency Rating (EER) or

8 | Milk Chilling Brochure

The iCONVERTER is a distributed cooling system which pumps chilled glycol to multiple points that require coolant. This means that multiple BMTs can be installed. Adding an additional BMT at a later stage is only a small plumbing change rather than a complete new compressor being fitted.

With glycol running through the base of the BMT it will never freeze milk to the dimple pad so cooling is applied right at the start of milking. Dimple pad maintenance is also greatly reduced.

4. Thermal Storage The iCONVERTER has its own thermal energy storage tank which works

as a battery, allowing the system to store the energy it needs to deliver the required cooling to snap chill the milk. This allows the dairy operation to shift electricity consumption to lower off peak power rates by running the iCONVERTER at night.

5. Snap Chilling The iCONVERTER uses phase change technology which allows it to store the energy required to instantaneously snap chill milk as it transfers through the plate heat exchanger. In simple terms, small balls are frozen solid using chilled glycol. This is where the energy is stored and only released as and when it is required to snap chill the milk.

Phase Change Nodules 98Ømm

Phase Change Nodules

Water

Stores 54 Kw/h Per 1m³ for every 1° Temp Change

Stores 4.1 Kw/h Per 1m³ for every 1° Temp Change

Plug Air pocket Phase Change Material (PCM) Phase Blend of polyolefines

Stores 54 Kw/h Per 1m³ for every 1° Temp Change

5,000 Litres with 5.2m³ of PCN

Stores 4.1 Kw/h Pe for every 1° Temp C

70,000 Litres of Chilled Water

iCONVERTER & Thermal Energy Storage Why can iCONVERTER release so much energy instantaneously?

The answer is not so simple due to something called ‘Latent Heat of Fusion’, so here is a simplified explanation: iCONVERTER uses Phase Change Nodule technology (special balls filled with a liquid solution) to encapsulate what is called Latent Energy. This allows iCONVERTER to store vast amounts of energy in a very small space. Think of them like chilly bin ice packs.

The iCONVERTER can use up to 6,800 phase change nodules. This gives them the same energy as you would find in 70,000 litres of chilled water.

How It Works Phase change nodules (PCN) are loaded into an insulated tank then filled with a food grade glycol. During the iCONVERTER’s charging mode, the glycol is chilled down to -5°C and pumped through the tank which freezes the nodules. This is just like putting a chilly bin pack in the freezer.

Once the system is fully charged the system is switched to milking mode. Glycol is pumped to the plate heat exchanger at 0°C which instantly snap chills the milk to typically less than 5°C. The glycol then returns to absorb the latent energy from the nodules.

How Is The Latent Heat (Thermal Storage) Measured?

Simply by multiplying a kW (joule per second) by 3,600,000 giving you a kilowatt hour kW/h. The measure of how many kW/h’s contained in a mass then gives you the level of its power to chill milk.

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The iCONVERTER Models The iCONVERTER range may be configured with many different options and sizes to meet any farm requirement, from direct online chilling to thermal storage utilising off peak power for maximum chilling efficiency. iCONVERTER aquaTESS Key Features • Snap Chills Milk to 5°C or less • Chills milk in the bulk milk tank • Eliminates milk from freezing to dimple pads • Has the ability to chill multiple bulk milk tanks simultaneously • Delivers free hot water at 60°C at 150 - 350 litres per hour depending on model • Energy Efficiency Rating (EER) of at least 3:1 during operating periods where outlet temperature is over 1ºC. • Significant average yearly savings when installed on a New Zealand farm.

Savings increase with longer milking times and larger herd numbers • Uses a significant amount of off peak power (typically up to 80%) Further to the base range GEA also offers bespoke solutions for large scale farming operations, typically 3000 cows and above.

10 | Milk Chilling Brochure

Above: iCONVERTER aquaTESS

iCONVERTER Diagram Office

Store room

Milk room

HOT WATER

Plant room

WASTE HOT AIR

HOT WATER

WASH TUB

11

2 MILKING SYSTEM

Danger Electricity

3

HOT

1

COLD

9 4

iCONVERTER

5

PLATE HEAT EXCHANGER

8

8 7

10 ENERGY STORAGE TANK (PHASE CHANGE NODULES)

BULK MILK TANK

6

1

Incoming electrical supply

4

Glycol supply

7

Glycol return

2

Hot water from heat recovery

5

Glycol return

8

Glycol supply

Hot milk from parlour

6

Milk delivery to Bulk Milk Tanks

9

3

Glycol energy in

10

Glycol energy out

11

Waste hot air

Ground water connection to Plate Heat Exchanger not shown

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iCONVERTER TESS Direct Online Glycol Glycol DX Split System Water Chiller with Heat Recovery DX System with iCONVERTER TESS Competitive Analysis Heat Recovery

$$

iCONVERTER TESS

TESS

$$

iCONVERTER

Competitive Analysis Yearly Running Cost

Capital Cost

Actual Cost yr 1

Actual Cost yr 2

Actual Cost yr 3

Actual Cost yr 4

Actual Cost yr 5

Actual Cost yr 6

Competitors

Cost of Ownership

iCONVERTER TESS

Direct Online Glycol

Typical Farm Power Consumption

Glycol DX Split System

Water Chiller with Heat Recovery

DX System with Heat Recovery

Typical Farm Power Consumption (Savings) Cooling Savings 7%

Other 11%

Water pumping 10%

Milking System 26%

Milking System 26% Hot Water Savings 30%

Water Heating 32%

Milk Cooling 21%

Milk Cooling 14% Other 11%

Water Pumping 10%

Water Heating 2%

A total of up to 37% of the total farm dairy energy consumption is reduced by the iCONVERTER system.

With the use of other variable speed and energy efficient devices installed at the dairy the overall energy footprint of the farm dairy is significantly less than traditional installations.

Competitive Analysis Every installation is different and therefore a detailed specification is provided with each quotation.

This calculates the cooling load and energy saving that you can expect from the iCONVERTER. The capital outlay with iCONVERTER is almost always higher than competitors products but it is the total cost of ownership over the short term that makes iCONVERTER a smart choice for a long term investment. Quality is remembered long after the price is forgotten.

Competitive Analysis

Running Costs

Typical Farm Power Consumption

The graph above shows the iCONVERTER against typical cooling solutions on the market today. iCONVERTER clearly demonstrates its efficiency after year three through significantly reduced yearly running costs.

Yearly running costs are often one third of competitor products and nearly half of all products currently on the market.

Savings that are created by an iCONVERTER system have a significant impact on reducing your overall farm dairy running costs. Typically power consumption for hot water heating and milk cooling represent 45% of the total energy used every day.

12 | Milk Chilling Brochure

Length Length

Height Height

Width Width

Technical Information

Capacity (Nominal)

O/A Length “A”

Diameter “W”

“H” (Minimum)

10,300

4,720

1,900

2,100

14,000

6,245

1,900

2,100

20,000

5,500

2,440

2,730

25,000

6,545

2,440

2,730

30,000

7,815

2,440

2,730

21,500

4,100

3,000

3,200

25,500

4,710

3,000

3,200

31,500

5,630

3,000

3,200

35,500

6,240

3,000

3,200

41,000

7,050

3,000

3,200

iCOOL Horizontal Direct Expansion Bulk Milk Tanks The DX-FF, offers the dairy farmer the ultimate in milk cooling technology.

High quality stainless steel, extreme efficiency and outstanding reliability ensure that the range of DX-FF tanks give top cooling and washing performance.

With a range of sizes from 10,300 to 41,000 litres, a range of profiles, bulk-head access styles and well thought out design, DX-FF tanks offer the flexibility to fit any location. With a vast array of options; compromise is not one of them!

With over forty years in stainless steel fabrication and heat transfer technology, you can be sure that we have the experience to create the bulk milk tank you can rely on.

All iCOOL tanks come with a 5 year pad warranty.

Key Features • Complete range from 10,300 to 41,000 litres • Highest quality and performance • Built to fit • Designed with technology

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Height

Width

Vertical Tanks: Double skinned and Glycol base Capacity (Nominal)

Diameter “W”

“H” (Minimum)

9,000

2,440

3,000

13,000

2,440

4,050

16,500

3,000

3,400

20,500

3,000

4,050

30,500

3,000

5,575

Single skinned variants are available on request.

iSTORE Vertical / Horizontal Direct Expansion or Liquid Circulation Bulk Milk Tanks The GEA iSTORE range of Bulk Milk Tanks, manufactured by DTS, offers excellent value.

Manufactured from stainless steel to meet food grade standards the hygienic design is suitable for storage of milk and other products such as wine and juices.

The tanks can be located inside the milking parlour or outside at the collection point.

This feature reduces building construction costs.

All iSTORE tanks come with a front entry manway and ladders are fitted to all silos.

Cooling is provided by direct expansion or liquid circulation through the laser welded dimple jacketed base plate or side walls. All sizes feature cooling which is further increased by the gull winged agitators.

With over 100 years experience in the dairy industry and manufacturing plants located in New Zealand, Australia, USA and China a cooling and storage solution is available to you. All iSTORE tanks come with a 5 year PAD warranty.

Heat Recovery

Polar Wraps

Key Features

• Make use of previously unused cooling compressor energy

• Increase overall cooling efficiency

• Standard sizes available from 11,500 to 30,500 litres

• Reduce the overall electricity expense of producing hot water • Increase hot water capacity

• Decrease the cycling of the cooling compressors • Decrease heating effect of direct sunlight • Decrease milk “baking on” above milk level • Can be retrofitted to any vertical tank

14 | Milk Chilling Brochure

• Vertical & horizontal options • Options of compressors and controls • CIP systems available

Complete Turnkey Solution GEA provides a comprehensive package that includes all components to complete the job (excludes electrical connection to supply).

CHILLER

THE KIT

PCN TANK

VAT TEMP CONTROLLERS BULK TANK (OPTIONAL) VAT CONTROLLER STANDS

DOUBLE BANK COOLER PIPES

HANDLE

WITH CARE

HANDLE CARE WITH

HANDLE

WITH CARE

HANDLE CARE WITH

HANDLE

WITH CARE

HANDLE CARE WITH

MANIFOLDS PCN PALLETS

GLYCOL BARRELS

ALL FITTINGS

ALL LABOUR

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We live our values.

Excellence • Passion • Integrity • Responsibility • GEA-versity GEA Group is a global engineering company with multi-billion euro sales and operations in more than 50 countries.

Founded in 1881, the company is one of the largest providers of innovative equipment and process technology.

GEA Group is listed in the STOXX® Europe 600 Index.

GEA Farm Technologies 12-14 Quail Place, Hamilton 3204 PO Box 5578, Frankton, Hamilton 3242 New Zealand Tel +64 7 873 1780 Fax +64 7 843 1779 0800 GEA FARM www.gea-farmtechnologies.co.nz