Ribs And Roast

Job Description: Installation Of A New Co2 Refrigeration System

The project presented several unique challenges that required a customized approach to achieve an optimal solution. A detailed presentation was provided to outline our comprehensive plan for project execution.

Our turnkey system encompassed the design and installation of advanced refrigeration and heating systems essential for cooking, cooling, and storing the cryovac product. We engineered a complete CO2 solution aimed at maximizing efficiency and minimizing operating costs, both in terms of electrical consumption and refrigerant usage. This bespoke system was meticulously designed to meet their specific operational requirements, integrating cutting-edge CO2 refrigeration technology.

For heating the product, we employed a gas-fired heater delivering 95 degrees Celsius water through a pressurized pipe network to individually controlled heat exchangers strategically located at the cook tanks. All piping was meticulously routed through the roof space to facilitate efficient movement of personnel and goods within the cooking area.

The project involved installing 8 large tanks and 8 small tanks dedicated to the cooking and cooling processes, totaling 16 tanks designed to manage heating and cooling operations. These tanks were mounted on stainless-steel frames to ensure ease of cleaning and provide adequate clearance for the intricate pipe network.

In accordance with the detailed heat load analysis provided by Ribs & Roast, we designed the system to handle peak heat loads during the initial 2 hours of the cooking process, with a capacity of 400 – 500 kilowatts and a safety margin for heat loss throughout the operation. Stainless steel gantries were also installed to support all 32 tanks, ensuring robust and reliable operational support.

To maintain operational continuity, we installed two storage tanks in the plant room—one for hot water and another for chilled water—dedicated to quick-fill operations in the event of potential product contamination in the cook-chill packing room.

For cooling operations throughout the facility, we exclusively utilized CO2 refrigerant, eliminating reliance on synthetic refrigerants to enhance efficiency and mitigate potential future cost increases and supply chain disruptions.

We also completed a freezer floor preparation project, which included raising the freezer floors above the existing concrete slab. This approach reduced installation costs and facilitated easier maintenance and repairs if necessary.

The raised freezer floor design incorporated provisions for warm glycol floor heating within the base slurry, followed by insulation installation, and concluded with pouring the final top concrete slab.

Additionally, we included 4 ramps designed at the same pitch as their previous facility, ensuring consistency and optimal functionality across their operations.