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iCONVERTER Chiller Range

iCONVERTER Chiller Range
Overview
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. As such, GEA has
developed a market leading snap chilling and heat recovery system called the iCONVERTER. 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.
Why Snap Chill Milk?
Milk starts to deteriorate the moment it is harvested from the cow.
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.
Key Features
Milk quality
37% energy savings
Factory compliance
Future proof your farm from
pending changes in milk
chilling standards
EFFLUENT
TECHNOLOGY
FARM
TOOLS
MANAGEMENT
SERVICE AT
FARMERS GATES
CONSULTANCY
HEALTH PRODUCTS
HYGIENE &
CONSULTANCY
HYGIENE
Milk Quality Compliance (The Regulatory Issues)
Million bacteria per ml
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.
900
500
10
3
1
0.3
30˚C
25˚C
Hours after milking
20˚C
0 4 8 12 16 20 24 28
15˚C
4˚C
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.
EQUIPMENT
BARN
SYSTEMS
MILKING
& COOLING
MILK STORAGE
AUTOMATIC
FEEDING
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iCONVERTER Chiller Range
& Thermal Energy Storage
Cooling and 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%.
The key benefits of the iCONVERTER are
shown below.
The diagram to the right shows the basic
relationship of each key aspect of the
iCONVERTER installed in the average
milking system.
2
3
4
5
LARGE ENERGY
SAVINGS
MULTIPLE BULK
MILK TANKS (BMT)
THERMAL STORAGE
SNAP CHILLING
1
FREE HOT
WATER
GENERATION
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.
Phase Change Nodules 98Ømm
Plug
Air pocket
Phase Change
Material (PCM)
Phase Blend of
polyolefines
1
Free Hot Water Generation
The iCONVERTER uses a new high pressure refrigerant called R410a. This allows the system to generate free
hot water at an average of 75°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.
2
3
4
5
Large Energy Savings
The iCONVERTER is classified as a ‘Class A’ efficiency refrigeration system. This means it has been tested and
certified to generate well over 3kW/h of chilling output for every 1kW/h of electricity input. This is more than
a 3:1 ratio. This ratio is often referred to as Energy Efficiency Rating (EER) or Coefficient of Performance (COP).
Multiple Bulk Milk Tanks (BMTs)
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.
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.
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 .
5,000 Litres with
5.2m³ of PCN
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.
70,000 Litres of Chilled Water
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.
Phase Change Nodules
Stores 54 Kw/h Per 1m³
for every 1° Temp Change
Water
Stores 4.1 Kw/h Per 1m³
for every 1° Temp Change
CENTRED AROUND YOUR FARM NOW & INTO THE FUTURE

iCONVERTER Chiller Range
The iCONVERTER Models
The iCONVERTER range consists of two base models, the aquaDIRECT for on demand chilling and the
aquaTESS which utilises thermal storage of off peak power for maximum chilling effi ciency.
Key Features
Diagram
iCONVERTER aquaDIRECT
Snap Chills Milk to 6°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 70-75°C
at 150-300 litres per hour depending
on model
Energy Efficiency Rating (EER) of 3.3
Typical average yearly saving of
$6,500.00 NZD when installed on a
New Zealand farm. Savings increase
with longer milking times and larger
herd numbers
MILKING SYSTEM
3
2
HOT
WATER
WASH TUB
HOT
WATER
11
WASTE HOT AIR
Danger
Electricity
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 70-75°C at
200-350 litres per hour depending
on model
Energy Efficiency Rating (EER) of 3.3
Typical average yearly saving of
$12,000.00 NZD 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%)
HOT
COLD
PLATE HEAT
EXCHANGER
4
5
iCONVERTER
8
7
8
10
9
1
ENERGY STORAGE TANK
(PHASE CHANGE NODULES)
BULK MILK TANK
6
Further to the base range GEA also offers the aquaDIRECT MEGA and the aquaTESS MEGA.
These are bespoke solutions for large scale farming operations, typically 3000 cows and above.
NEW
1 Incoming electrical supply 4 Glycol supply 7 Glycol return 10
2
Glycol energy out
Hot water from heat recovery 5 Glycol return 8 Glycol supply 11 Waste hot air
3 Hot milk from parlour 6 Milk delivery to Bulk Milk Tanks 9 Glycol energy in Ground water connection to
Plate Heat Exchanger not shown
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iCONVERTER Chiller Range
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
$$
Capital
Cost
Actual
Cost yr 1
iCONVERTER TESS
iCONVERTER TESS
Actual
Cost yr 2
Competitve Analysis
iCONVERTER TESS Competitive Analysis
Actual
Cost yr 3
Cost of Ownership
Direct Online Glycol
Actual
Cost yr 4
Actual
Cost yr 5
Glycol DX Split System
Actual
Cost yr 6
The graph above shows the iCONVERTER against typical
cooling solutions on the market today. iCONVERTER clearly
demonstrates its efficiency after year three through
significantly reduced yearly running costs.
Typical Farm Power Consumption
$$
iCONVERTER TESS
Water Chiller with Heat Recovery
Running Costs
Competitive Analysis Yearly Running Cost
Competitors
DX System with Heat Recovery
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.
Horizontal Direct Expansion Bulk Milk Tanks
The GEA 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.
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
Key Features
Complete range from 10,300 to
41,000 litres
Highest quality and performance
Built to fit
Designed with technology
Width
Typical Farm Power Consumption
Water
pumping
10%
Other
11%
Water Heating
32%
Milking System
26%
Milk Cooling
21%
Typical Farm Power Consumption (Savings)
Cooling Savings
7%
Hot Water Savings
30%
Other
11%
Water
Pumping
10%
Milking System
26%
Milk Cooling
14%
Water Heating
2%
A total of 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.
Length
Height
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iCONVERTER Chiller Range
Complete Turnkey Solution
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
Make use of previously unused cooling compressor
energy
Reduce the overall electricity expense of producing hot
water
Short payback time
Increase hot water capacity
Polar Wraps
Increase overall cooling efficiency
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
Key Features
Standard sizes available from 11,500 to
30,500 litres
Vertical & horizontal options
Options of compressors and controls
CIP systems available
Vertical Tanks
Double skinned and Glycol base
Capacity
(Nominal)
Width
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.
Height
GEA provides a comprehensive package that includes all components to complete the job (excludes electrical
connection to supply).
HANDLE
WITH CARE
THE KIT
PCN PALLETS
HANDLE
WITH CARE
HANDLE
WITH CARE
HANDLE
WITH CARE
DOUBLE BANK
COOLER
HANDLE
WITH CARE
HANDLE
WITH CARE
GLYCOL BARRELS
CHILLER
VAT TEMP
CONTROLLERS
PIPES
ALL FITTINGS
ALL LABOUR
PCN TANK
VAT
CONTROLLER
STANDS
BULK TANK
(OPTIONAL)
MANIFOLDS
CENTRED AROUND YOUR FARM NOW & INTO THE FUTURE