Refrigeration Plant Replacement
Overview
TPG managed the replacement of outdated R22 refrigeration compressors with a more efficient and sustainable ammonia-based system. This initiative addresses key operational, environmental, and compliance concerns while ensuring long-term reliability and efficiency for the facility’s refrigeration needs.
The existing R22 and 404A gas systems are outdated, environmentally harmful, and no longer commercially available, posing a high risk of downtime. The new ammonia-based system will improve energy efficiency, reduce maintenance costs, and align with sustainability goals by lowering greenhouse gas emissions and integrating heat recovery technology.
Project Scope
Replacement of R22 Chillers & Frascold Screw Compressors with new ammonia-based refrigeration units.
Integration of Procomac glycol system into a central glycol distribution network for greater efficiency.
Installation & commissioning of a 2000 kWr refrigeration package to support plant operations.
Electrical upgrades to support the new system.
Process piping modifications and plant infrastructure improvements.
Construction & modification of the plant room to house the new system.
Project management & commissioning to ensure seamless implementation.
The project is expected to generate significant energy savings (250,000 kWh per annum), reduce maintenance costs by $150K annually, and enhance long-term operational stability. This upgrade ensures compliance with environmental regulations and enhances manufacturing efficiency at the site.
Key Benefits
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Cost Savings
Reduces maintenance costs by $150K annually
Saves 250,000 kWh per year in energy consumption
Eliminates costly R22 refrigerant refills due to leaks
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Sustainability
TReplaces ozone-depleting R22 refrigerant with eco-friendly ammonia
Enhances energy efficiency with heat recovery technology
Supports long-term compliance with environmental regulations
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Consumer Impact
Ensures consistent refrigeration performance, reducing production risks
Supports sustainable manufacturing, meeting consumer demand for eco-friendly practices
Improves supply chain reliability by minimizing downtime and disruptions
Outcome:
TPG successfully replaced legacy R22 chillers with high-efficiency ammonia-based systems for a leading beverage manufacturer.
The upgrade delivered improved energy performance, reduced environmental impact, and ensured full compliance with refrigerant phase-out regulations.
The project was completed without disrupting production, providing a reliable and sustainable long-term solution.
