Cooling Brochure Proof

iCONVERTER Chiller Range

CENTRED AROUND YOUR FARM NOW & INTO THE FUTURE

iCONVERTER Chiller Range

OverviewCentral to the function of every dairy farm is the collection and storage of milk.

Milk quality can only be guaranteed when the milk cooling process is effi cient and reliable. As such, GEA has developed a market leading snap chilling and heat recovery system called the iCONVERTER. GEA also has two hygienic storage solutions available. Both offer excellent energy effi ciency and cooling characteristics to meet the need of any installation.

Whether it is a standard solution for storage of milk or an integrated solution which takes in smart controls, an automated cleaning system, snap chilling and energy saving heat recovery, GEA has a solution to meet your cooling needs.

AUTOMATIC

FEEDING

CONSULTANCY

HYGIENE &

HEALTH PRODUCTS

HYG

IENE

CO

NSU

LTAN

CY

MILKING

SYSTEMS

MILK STOR

AGE & COOLING

BARN

EQUI

PMEN

T

EFFL

UEN

TTE

CH

NO

LOG

YFA

RMM

ANAG

EMEN

T

FARMER

S GATES

SERVICE

AT

TOOL

S

Hours after milking

4C

15C

20C30C

25C

Mill

ion

bact

eria

per

ml 900

500

10

3

40 8 12 16 20 24 28

10.3

Key Features Milk quality 37% energy savings Factory compliance Future proof your farm from

pending changes in milk chilling standards

Milk starts to deteriorate the moment it is harvested from the cow.

Naturally occurring bacteria in the milk starts multiplying straight away and only temperature can slow the process down to preserve milk quality.

Needless to say then, snap chilling milk has a number of fundamental benefi ts for both the milk producer and the processor.

High quality milk has a longer shelf life and can be processed into more high value products than raw milk that has higher levels of bacteria.

Why Snap Chill Milk?

This graph clearly demonstrates why milk processors insist on milk being chilled to 4C as quickly as possible at the end of milking.The lower the milk temperature into the Bulk Milk Tank, the lower the bacteria or bacto count when the processor collects the milk.Note: Below 10C bacteria growth is seriously reduced and is practically stopped at 4C.

Milk Quality Compliance (The Regulatory Issues) Bactoscan (bacteria count, milk chilling related) Thermoduric (heat resistant bacteria) Coliforms (wet weather / manure bacteria)

All of the above issues can be greatly improved by snap chilling and high grade heat recovery for maximum plant hygiene.

CENTRED AROUND YOUR FARM NOW & INTO THE FUTURE

iCONVERTER Chiller Range

Free Hot Water GenerationThe iCONVERTER uses a new high pressure refrigerant called R410a. This allows the system to generate free hot water at an average of 75C, giving plenty of hot water for maximum plant hygiene. Spare hot water can be used for other uses such as re-heating calf milk, plant washing etc.

Large Energy SavingsThe iCONVERTER is classifi ed as a Class A effi ciency refrigeration system. This means it has been tested and certifi ed to generate well over 3kW/h of chilling output for every 1kW/h of electricity input. This is more than a 3:1 ratio. This ratio is often referred to as Energy Effi ciency Rating (EER) or Coeffi cient of Performance (COP).

Multiple Bulk Milk Tanks (BMTs)The iCONVERTER is a distributed cooling system which pumps chilled glycol to multiple points that require coolant. This means that multiple BMTs can be installed. Adding an additional BMT at a later stage is only a small plumbing change rather than a complete new compressor being fi tted. With glycol running through the base of the BMT it will never freeze milk to the dimple pad so cooling is applied right at the start of milking. Dimple pad maintenance is also greatly reduced.

Cooling and Heating CellThe iCONVERTER is an All-in-One Cell designed specifi cally for on-farm milking, heating and cooling management.

The hybrid cell design is totally unique, delivering superior energy performance over all other solutions available on the market today.

The iCONVERTER can typically reduce total energy consumption of the farm dairy by as much as 37%.

The key benefi ts of the iCONVERTER are shown below.

The diagram to the right shows the basic relationship of each key aspect of the iCONVERTER installed in the average milking system.

1

2

3

Thermal StorageThe iCONVERTER has its own thermal energy storage tank which works as a battery, allowing the system to store the energy it needs to deliver the required cooling to snap chill the milk. This allows the dairy operation to shift electricity consumption to lower off peak power rates by running the iCONVERTER at night.

4

Snap ChillingThe iCONVERTER uses phase change technology which allows it to store the energy required to instantaneously snap chill milk as it transfers through the plate heat exchanger. In simple terms, small balls are frozen solid using chilled glycol. This is where the energy is stored and only released as and when it is required to snap chill the milk

5

1

2

FREE HOT WATER GENERATION

LARGE ENERGY

SAVINGS

MULTIPLE BULK MILK TANKS (BMT)

THERMAL STORAGE

SNAP CHILLING

3

4

5

.

Why can iCONVERTER release so much energy instantaneously?The answer is not so simple due to something called Latent Heat of Fusion, so here is a simplifi ed explanation:

iCONVERTER uses Phase Change Nodule technology (special balls fi lled with a liquid solution) to encapsulate what is called Latent Energy.

This allows iCONVERTER to store vast amounts of energy in a very small space.

Think of them like chilly bin ice packs.

The iCONVERTER can use up to 6,800 phase change nodules. This gives them the same energy as you would fi nd in 70,000 litres of chilled water.

Phase Change Nodules 98mm

Phase Change Nodules Water

How It WorksPhase change nodules (PCN) are loaded into an insulated tank then fi lled with a food grade glycol.

During the iCONVERTERs charging mode, the glycol is chilled down to -5C and pumped through the tank which freezes the nodules. This is just like putting a chilly bin pack in the freezer.

Once the system is fully charged the system is switched to milking mode. Glycol is pumped to the plate heat exchanger at 0C which instantly snap chills the milk to typically less than 5C.

The glycol then returns to absorb the latent energy from the nodules.

How Is The Latent Heat(Thermal Storage) Measured?Simply by multiplying a kW (joule per second) by 3,600,000 giving you a kilowatt hour kW/h.

The measure of how many kW/hs contained in a mass then gives you the level of its power to chill milk.

Stores 4.1 Kw/h Per 1mfor every 1 Temp Change

5,000 Litres with5.2m of PCN 70,000 Litres of Chilled Water

Plug

Air pocket

Phase Change Material (PCM)

Phase Blend of polyolefines

Stores 54 Kw/h Per 1mfor every 1 Temp Change

& Thermal Energy Storage

CENTRED AROUND YOUR FARM NOW & INTO THE FUTURE

iCONVERTER Chiller Range

The iCONVERTER ModelsThe iCONVERTER range consists of two base models, the aquaDIRECT for on demand chilling and the aquaTESS which utilises thermal storage of off peak power for maximum chilling effi ciency.

Further to the base range GEA also offers the aquaDIRECT MEGA and the aquaTESS MEGAThese are bespoke solutions for large scale farming operations, typically 3000 cows and above.

Key Features Snap Chills Milk to 6C or less Chills milk in the bulk milk tank Eliminates milk from freezing to

dimple pads Has the ability to chill multiple bulk

milk tanks simultaneously Delivers free hot water at 70-75C

at 150-300 litres per hour depending on model

Energy Effi ciency Rating (EER) of 3.3 Typical average yearly saving of

$6,500.00 NZD when installed on a New Zealand farm. Savings increase with longer milking times and larger herd numbers

iCONVERTER aquaTESS

Key Features Snap Chills Milk to 5C or less Chills milk in the bulk milk tank Eliminates milk from freezing to

dimple pads Has the ability to chill multiple bulk

milk tanks simultaneously Delivers free hot water at 70-75C at

200-350 litres per hour depending on model

Energy Effi ciency Rating (EER) of 3.3 Typical average yearly saving of

$12,000.00 NZD when installed on a New Zealand farm. Savings increase with longer milking times and larger herd numbers

Uses a signifi cant amount of off peak power (typically up to 80%)

NEW.

iCONVERTER aquaDIRECT

1 Incoming electrical supply 4 Glycol supply 7 Glycol return 10 Glycol energy out

2 Hot water from heat recovery 5 Glycol return 8 Glycol supply 11 Waste hot air

3 Hot milk from parlour 6 Milk delivery to Bulk Milk Tanks 9 Glycol energy in Ground water connection to Plate Heat Exchanger not shown

HOT

COLD

DangerElectricity

D

2 11

1

3

6

9

10

7

88

4

5

BULK MILK TANK

WASTE HOT AIR

WASH TUB

MILKING SYSTEM

iCONVERTER

ENERGY STORAGE TANK (PHASE CHANGE NODULES)

HOTWATER

HOTWATER

PLATE HEAT EXCHANGER

Diagram

CENTRED AROUND YOUR FARM NOW & INTO THE FUTURE

iCONVERTER Chiller Range

Cooling Savings7%

Water Heating2%

Hot Water Savings30%

WaterPumping

10%

Milking System26%

Milk Cooling14%

Other11%

Water pumping

10%

Water Heating32%

Milking System26%

Milk Cooling21%

Other11%

Competitors

$$

iCON

VERT

ER T

ESS

Cost of Ownership

$$

CapitalCost

ActualCost yr 1

ActualCost yr 2

ActualCost yr 3

ActualCost yr 4

ActualCost yr 5

ActualCost yr 6

iCONVERTER TESS

Every installation is different and therefore a detailed specifi cation is provided with each quotation. This calculates the cooling load and energy saving that you can expect from the iCONVERTER.

The capital outlay with iCONVERTER is almost always higher than competitors products but it is the total cost of ownership over the short term that makes iCONVERTER a smart choice for a long term investment. Quality is remembered long after the price is forgotten

Competitive Analysis

Competitve AnalysisThe graph above shows the iCONVERTER against typical cooling solutions on the market today. iCONVERTER clearly demonstrates its effi ciency after year three through signifi cantly reduced yearly running costs.

Running CostsYearly running costs are often one third of competitor products and nearly half of all products currently on the market.

A total of 37% of the total farm dairy energy consumption is reduced by the iCONVERTER system. With the use of other variable speed and energy effi cient devices installed at the dairy the overall energy footprint of the farm dairy is signifi cantly less than traditional installations.

Typical Farm Power ConsumptionSavings that are created by an iCONVERTER system have a signifi cant impact on reducing your overall farm dairy running costs. Typically power consumption for hot water heating and milk cooling represent 45% of the total energy used every day.

iCONVERTER TESS Competitive Analysis

Typical Farm Power Consumption Typical Farm Power Consumption (Savings)

Competitive Analysis Yearly Running Cost

Glycol DX Split SystemDirect Online Glycol DX System with Heat RecoveryWater Chiller with Heat RecoveryiCONVERTER TESS

Key Features Complete range from 10,300 to

41,000 litres Highest quality and performance Built to fi t Designed with technology

Horizontal Direct Expansion Bulk Milk TanksThe GEA DX-FF, offers the dairy farmer the ultimate in milk cooling technology.

High quality stainless steel, extreme effi ciency and outstanding reliability ensure that the range of DX-FF tanks give top cooling and washing performance.

With a range of sizes from 10,300 to 41,000 litres, a range of profi les, bulk-head access styles and well thought out design, DX-FF tanks offer the fl exibility to fi t any location. With a vast array of options; compromise is not one of them!

With over forty years in stainless steel fabrication and heat transfer technology, you can be sure that we have the experience to create the bulk milk tank you can rely on.

All iCOOL tanks come with a 5 year pad warranty.

Heigh

t

Length

WidthTechnical InformationCapacity

(Nominal)O/A Length

ADiameter

WH

(Minimum)

10,300 4,720 1,900 2,100

14,000 6,245 1,900 2,100

20,000 5,500 2,440 2,730

25,000 6,545 2,440 2,730

30,000 7,815 2,440 2,730

21,500 4,100 3,000 3,200

25,500 4,710 3,000 3,200

31,500 5,630 3,000 3,200

35,500 6,240 3,000 3,200

41,000 7,050 3,000 3,200

CENTRED AROUND YOUR FARM NOW & INTO THE FUTURE

iCONVERTER Chiller Range

Key Features Standard sizes available from 11,500 to

30,500 litres Vertical & horizontal options Options of compressors and controls CIP systems available

Vertical / Horizontal Direct Expansion or Liquid Circulation Bulk Milk TanksThe GEA iSTORE range of Bulk Milk Tanks, manufactured by DTS, offers excellent value. Manufactured from stainless steel to meet food grade standards the hygienic design is suitable for storage of milk and other products such as wine and juices.

The tanks can be located inside the milking parlour or outside at the collection point. This feature reduces building construction costs.

All iSTORE tanks come with a front entry manway and ladders are fi tted to all silos.

Cooling is provided by direct expansion or liquid circulation through the laser welded dimple jacketed base plate or side walls. All sizes feature cooling which is further increased by the gull winged agitators.

With over 100 years experience in the dairy industry and manufacturing plants located in New Zealand, Australia, USA and China a cooling and storage solution is available to you.

All iSTORE tanks come with a 5 year PAD warranty.

Heat Recovery Make use of previously unused cooling compressor

energy Reduce the overall electricity expense of producing hot

water Short payback time Increase hot water capacity

Polar Wraps Increase overall cooling effi ciency Decrease the cycling of the cooling compressors Decrease heating effect of direct sunlight Decrease milk baking on above milk level Can be retrofi tted to any vertical tank

Width

Heigh

t

Capacity(Nominal)

DiameterW

H(Minimum)

9,000 2,440 3,00013,000 2,440 4,05016,500 3,000 3,40020,500 3,000 4,05030,500 3,000 5,575

Single skinned variants are available on request.

Vertical TanksDouble skinned and Glycol base

Complete Turnkey Solution

HANDLEWITH CARE

HANDLEWITH CARE

HANDLEWITH CARE

HANDLEWITH CARE

HANDLEWITH CARE

HANDLEWITH CARE

HANDLEWITH CARE

CHILLER

PCN TANK

BULK TANK(OPTIONAL)

VAT CONTROLLER

STANDS

VAT TEMP CONTROLLERS

DOUBLE BANK COOLER

PIPES

MANIFOLDS

ALL LABOUR

ALL FITTINGSGLYCOL BARRELS

PCN PALLETS

THE KIT

GEA provides a comprehensive package that includes all components to complete the job (excludes electrical connection to supply).