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Ammonia system dramatically reduces energy use and carbon

01 May 2024

Pilgrim UK's meat processing facility at Bromborough has dramatically reduced its energy costs and carbon emissions following the installation of a high efficiency ammonia refrigeration system by Demeva Refrigeration.

Energy costs for the previous cooling system used at the site were £146,000 a year, compared with an estimated £61,000 for the new solution, offering savings of over £80,000 a year in running costs – a reduction of nearly 60% – and delivering substantial savings in carbon emissions.

Demeva Refrigeration specified a 707kW BITZER Ammonia Compressor Pack (ACP), powered by screw compressors, to replace an end-of-life ammonia system that had been in service for 20 years. The existing ammonia charge was retained for use in the new system, further supporting the economic case for the upgrade.

The new system provides primary cooling at an evaporating temperature of -9°C for the site's secondary glycol circuit, serving cold stores at 2°C and air handling units at 8°C within the processing facility.

Timing on the project was critical due to the need to ensure continuity of cooling at the facility. This was assisted by being able to run the system’s second compressor during the switchover.

A logistical challenge was removing the old system and locating the new pack in position in the plant room. This required relatively straightforward modifications to pipework to connect the ACP pack to the central glycol system, followed by electrical connection.

"It was the first BITZER ACP pack we have installed," said Dean Rawling, Director at Demeva. "Having assessed the technology currently available on the market, we believe BITZER's ACP system is the most efficient ammonia refrigeration solution available."

Pay-back times
A key target for the project was to achieve pay-back on investment within one to one-and-a-half years. This was achieved as a result of the significant energy savings. Other energy saving measures implemented at the site include replacement of the evaporative condenser for the refrigeration pack, installation of modern high efficiency glycol pumps on the secondary circuit, and a new Building Energy Management System to provide site-wide monitoring.

Commenting on the project, Neil George, Engineering Manager at Pilgrim UK, said: "Responsible energy use is a major area of focus for our business. We are constantly looking for opportunities to improve energy efficiency and reduce emissions. The BITZER ACP pack, combined with the other efficiency measures implemented by Demeva Refrigeration, will significantly reduce power consumption and deliver significant savings in carbon emissions."

In addition to the inherent efficiency of screw compressors, the speed of the lead compressor is controlled by an integrated Variable Speed Drive (VSD), which significantly increases part-load efficiency and enables soft-start, important on sites where power headroom is limited. The BITZER solution is designed to meet the requirement for very high efficiency cooling for industrial applications with a zero Global Warming Potential (GWP) refrigerant. 


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