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Central Glycol

CENTRAL GLYCOL  SYSTEMS BAKERY

Our company has been providing centralized industrial cooling systems for over 15-years with numerous installations in bakeries throughout the United States. We pride ourselves on innovation and value and explored what could be done to not only meet product temperature requirements but also address other key elements including diversity, energy efficiency and ease of maintenance. This commitment to excellence has earned us the respect our customers as well as major bakery equipment vendors that know our systems will deliver adequate cooling to their devices and several have even employed our services to troubleshoot problem systems installed by other vendors.

ENGINEERING & INSTALLATION
Engineering and installation of our glycol refrigeration systems are typically accomplished with packaged air-cooled chillers that require no interior equipment room and even the circulating pumps can be mounted outdoors freeing up valuable floor space. Circulating loops can serve all of the plant process cooling requirements even if design temperatures vary so mixers, ice water, rounder beds, cold hold tanks, etc. can be operated on the same system.

Circulating loops are typically constructed with steel piping and insulated with closed cell insulation and jacketing as required. Loop configuration is a primary and secondary, which allows variable flow adjustment to meet loop demand requirements with 80% redundancy. Each usage point has an automatic control valve that can be manually positioned in the event of a failure and combined with an automatic balancing valve to maintain precise flow rates. Glycol management system is provided to automatically maintain system charge with a portable spill containment unit. System is completely automated and has the capacity for both in-plant and remote monitoring, alarming, and control.

ENERGY SAVINGS
Our systems are simple to operate and typically use 1/3 less energy than other design concepts by incorporating loop designs that maximize the chiller performance. Condensers are oversized providing lower condensing temperatures that compete with water-cooled chillers efficiencies while eliminating water treatment and increased maintenance costs. Other energy saving features include variable frequency drives for flow control and direct digital web based control systems.

ENVIRONMENTAL BENEFITS
Environmental impacts now and in the future are a major consideration as we all commit to managing air and water quality and implementing our glycol refrigeration system design concept is a positive step by conserving energy and eliminating several hundred tons of Greenhouse Gas emissions per year. In addition refrigerant charges are normally less than ½ those of built up systems.

CONCLUSION
Considering all the benefits of our glycol refrigeration system it is hard to imagine constructing a bakery without employing our enhanced design features that satisfy the bakery requirements of “Time & Temperature”. New installations in most cases will pay for themselves quickly when compared against a “standard system” and there is also ample opportunity to retrofit existing plants.

Scott G. Houtz is President of Air Management Technologies, Inc., a mechanical design-build contracting and energy consulting firm located in Lewisburg, PA. E-mail him at [email protected]

 

Central Glycol

Oxidizer / Oven Heat

OXIDIZER/OVEN HEAT RECOVERY SYSTEMS BAKERIES 

Several years ago Air Management Technologies was approached to develop a way to eliminate the use of boilers in bakeries, as well as reduce energy cost. It may have seemed a little far fetched at the time but it is now a reality with several successful installations throughout the United States and Canada. Today if you were to visit one of these plants you would find no boiler room, but you would find an innovative heat recovery system supplying proofers, fermentation rooms, and other end uses with more than enough heat to satisfy their load requirements.

OLD SCHOOL
Steam boilers have been the traditional way of providing process heating in bakeries for many years and given their ability to directly satisfy the humidification “wet-heat” requirements while providing a reliable heat source was a good fit. Times have changed with energy costs more than doubling over the past few years and with volatility still a major concern efforts must be taken to remain competitive. Oven/Oxidizer heat recovery is a step in the right direction as it eliminates the need for a traditional boiler room and the building cost associated. Combine this with lower installation costs versus steam, as well as decreased maintenance and energy costs, while being environmentally friendly and you have a Win-Win project.

ENGINEERING & DESIGN
Engineering and installation of the heat recovery system is accomplished by combining our expertise in managing the efficient distribution and control of the energy source with capturing the generated waste heat from the oven(s) or oxidizer exhaust streams which results in complete system with guaranteed savings.

The system can serve various points of usage including proofers, fermentation rooms, plant water heating, feedwater, CIP, space heating, etc. System operation is accomplished by utilizing heat from the oven exhaust stream that passes thru the plants oven(s) and / or catalytic oxidizer which is equipped with a recovery coil and control elements to regulate the heating output. Two outdoor gas-fired copper-tube water heaters with a footprint about double the size of a residential air conditioner serve several purposes including backup in the event of primary system failure, operate during cold starts, and as a peaking device to maximize recovered energy.

Central hot water distribution loop provides heating from the recovery system to end uses at a temperature between 200º-210ºF, and by incorporating a combination of compressed air atomization and high-pressure humidification systems to proofers and fermentation rooms both dry and wet heat loads are satisfied at a fraction of the cost. Control of the processes is maintained by a combination of direct digital controls and interfaces with vendor equipment.

GUARANTEED ENERGY SAVINGS
The system is monitored 24/7 by a web-based controller that allows a window into the system and logging of performance to verify savings with two line plant savings can be in excess of $60,000 per year. This system also provides a degree of protection against natural gas price volatility as savings will increase proportionally with natural gas prices. Heat recovery is also very efficient in delivery of the energy source greater than 98% when compared to traditional boilers at 70%.

Whenever implementing a project like this return on investment is a primary concern and with new installations the cost is completely defrayed by eliminating the conventional steam boilers so savings begin immediately providing a positive cash flow.

ENVIRONMENTAL BENEFITS
Environmental impacts now and in the future are a major consideration as we see an increased commitment to managing air and water quality to improve the environment. This is a major driving force behind this type of project which will eliminate several hundred tons of Greenhouse Gas emissions per year.

CONCLUSION
Considering all the benefits of heat recovery it is hard to imagine ever constructing a bakery without implementing this design concept. New installations in most cases will provide a positive cashflow from startup, but there is also ample opportunity to retrofit existing plants with typical returns ranging from 15-25%. These retrofit costs can be offset to provide a quicker return when capital can be attributed due to a need to replace or upgrade existing boilers.

Heat recovery can be applied in facilities with or without oxidizers. Oxidizers have an advantage with increased availability of heat and centralized heat exchangers but recovery can also be implemented in facilities that don’t have oxidizers and still satisfy production heat load requirements. This technology has also been explored in other industry sectors including Snack Foods with positive results.

Scott G. Houtz is President of Air Management Technologies, Inc. a mechanical design-build contracting and energy consulting firm located in Lewisburg, PA. E-mail him at [email protected]

Oxidizer / Oven Heat

Product Cooling

SELF-CONTAINED SPIRAL & CONTINUOUS COOLER ENVIRONMENTAL CONTROL SYSTEM

Several years ago Air Management Technologies was contacted to provide an environmental control system to condition a room that housed three (3) spiral bread coolers. It could have been considered a fairly straight forward project but at Air Management we pride ourselves on innovation and value, so we explored what could be done to not only meet product temperature requirements but also address other key elements, which included consistency, protection from molds, sanitation, product quality, energy efficiency and ease of maintenance.

ENGINEERING & INSTALLATION
Engineering and installation of the cooler environmental systems is accomplished by providing a custom roof-mounted air handling system that maintains a constant discharge air temperature regardless of outdoor or plant ambient conditions. Supply air is distributed through air ducting typically around three sides of the cooler providing an invisible air curtain which allows the use of this system even when it can’t be enclosed in a room. When mechanical cooling is required typically at outside air temperatures above 70ºF, a refrigeration condensing unit or remote utility (ammonia, chilled water) is provided and coupled to an evaporator to maintain proper temperature and humidity control.

Exhaust air is pulled from the center of the cooler which is the warmest and most humid location and can be exhausted, re-circulated or mixed with outdoor air depending on the mode of operation and room pressurization requirements. This operational mode allows discharging of excessive humidity in the summer when not desired and reclaiming of humidity in winter months to minimize product drying. Each unit is equipped with medium efficiency air filtration that removes over 90% of ambient mold spores providing decreased product exposure in comparison with other cooler designs. Systems also incorporate a direct digital controller that maintains control functions and with a phone line or web interface a direct link to our office for system monitoring.

ENERGY SAVINGS
Our spiral cooler environmental systems use less than a third of energy required for traditional coolers using refrigeration based systems that re-circulate air and are so efficient that many times we can replace existing systems with a payback in less than 5-years.

ENVIRONMENTAL BENEFITS
Environmental impacts now and in the future are a major consideration as we all commit to managing air and water quality and implementing our cooler environmental conditioning design concept is a positive step by conserving energy and eliminating several hundred tons of Greenhouse Gas emissions per year.

CONCLUSION
Considering all the benefits of a self-contained spiral cooling system it is hard to imagine ever constructing a bakery without implementing this technology. New installations in most cases will pay for themselves quickly when their premium if any is compared against a “standard system” and there is also ample opportunity to retrofit existing plants with typical returns ranging from 15-25%.

Scott G. Houtz is President of Air Management Technologies, Inc. a mechanical design-build contracting and energy consulting firm located in Lewisburg, PA. E-mail him at [email protected]

Product Cooling