AFI was approached to provide automation support for integrating a 4.5MW heat recovery system for one of the largest meat works in the South Island. The project aimed to recover wasted heat generated by the site’s refrigeration plant, transforming it into a more sustainable, energy-efficient system.

Previously, the main refrigeration plant relied on multiple cooling towers and condensers to cool compressors and condense ammonia using river water. However, through a significant redesign, this system was completely overhauled.

Two 2MW heat pumps and multiple heat exchangers were installed to replace the cooling towers, all while keeping production uninterrupted thanks to the careful staging of the commissioning process. To further enhance efficiency, the refrigeration plant’s PLC software was upgraded, simplifying the process for operators, who now have minimal interaction beyond simple start and stop commands.

AFI played a pivotal role in developing the functional description of the plant’s operation, while also taking a hands-on approach to project management, changeover, and the commissioning process. This attention to detail ensured the seamless integration of the new system with no production stoppages.

“The results have been impressive. The new heat recovery system has drastically reduced the carbon footprint of the site by saving around 100 tons of coal per week, allowing the main coal boiler to be shut down.”

At full capacity, the system can produce over 75,000 liters of water at 65°C per hour. Previously, this was wasted heat, but it is now being utilized to preheat water for the biomass boiler, improving overall energy efficiency.