We are a Chinese team specializing in cooling equipment. We have been in this field for many years. Our evaporative condensers and closed cooling towers are used worldwide to keep things cold. New Zealand is one of our markets, where dairy products like milk, cheese, and butter are very important to the economy. We partnered with a large dairy plant in Waikato. They have a big operation with milk pasteurization and cream production. Their old cooling system was causing problems, but our evaporative condensers improved efficiency and saved them a lot of money.
In the dairy business, everything moves quickly. Fresh milk needs to be pasteurized, cooled, and processed fast, making efficient cooling essential. Pasteurizers, chillers, and storage tanks require precise temperature control to prevent milk spoilage. If the temperature is wrong, the milk quality declines, and regulatory authorities could shut the plant down. The Waikato plant was struggling with its outdated cooling system. It had an open design with leaks, high energy consumption, and hard water that clogged pipes. New Zealand’s clean but wet weather, with rainy and windy summers around 20°C, was too much for the old system. Additionally, there were concerns about hygiene with dirty water near the milk, especially since key export markets like China and Australia had strict standards.
Their operations manager reached out to us, and we visited Waikato to examine the plant. We found that their pasteurizers were overheating, chillers were inconsistent, and energy costs were excessive. They were losing 4% of their milk batches due to temperature fluctuations, frustrating their buyers. We proposed our EC-550 evaporative condensers, which are 550 kW each and made of stainless steel to prevent rust. These use a food-grade ammonia system with smart controls for better power savings. The plant reviewed our proposal, saw the advantages, and agreed to proceed.
Installation Process
We installed three EC-550 evaporative condensers to support the pasteurizers and chilling tanks. The ammonia-based system is suitable for dairy operations, and the VFD fans offer energy efficiency. The PLC controls were connected to their monitoring system for seamless integration. We set up the system during a slower season to minimize disruptions in milk production. The installation took 11 days, during which our team trained their staff on coil checks, pressure monitoring, and filter cleaning. Given New Zealand’s mineral-rich water, which can cause scale build-up, we added a water treatment unit to keep the condensers clean.
Challenges Faced
New Zealand’s weather is unpredictable, with wet and windy conditions and temperatures ranging from 10°C to 25°C. The condensers had to be adaptable, so we fine-tuned the fans to maintain stable cooling. Although the power grid was dependable, the plant had older wiring, so we upgraded some circuits to avoid outages. The old piping was also an issue due to corroded joints, and we replaced them, which slightly extended the project timeline. The plant manager, Mr. Callum, remained calm and encouraged us to ensure long-term reliability. We worked hard to meet his expectations.
Mr. Callum’s Feedback
Mr. Callum has led the Waikato plant for ten years and is well-versed in dairy operations. Six months after installing our condensers, he shared his observations. He noted that their old cooling system was costly due to leaks, high power bills, and constant repairs. Our evaporative condensers have been transformative, reducing their energy costs by 23%. The fans adapt to cooler weather, saving money, while the pasteurizers hold steady at 72°C and chillers at 4°C, preventing milk spoilage. Their loss in milk batches decreased from 4% to under 0.8%, satisfying buyers in China and Australia. Maintenance is straightforward with no rust or grime, and their team checks the system bi-weekly. They’re now processing 18% more milk daily, leading to increased exports.
Improvements Made
Mr. Callum has the data to prove it—energy use decreased significantly with the VFD fans cutting power by nearly 25%. Water costs went down by 22% as the condensers use less water than open systems. Hygiene is critical in the dairy industry, and our system maintains cleanliness. Production increased by 18%, allowing them to handle more milk efficiently without chiller failures, meeting the quality standards required by China and Australia. Our stainless steel condensers withstand Waikato’s damp air, and the PLC system provides real-time data to identify issues early, minimizing downtime. Mr. Callum’s team appreciates its simplicity; we left manuals in English and conducted a follow-up visit to ensure everything was working well.
Success in New Zealand
Dairy is vital to New Zealand’s economy, supplying half of the world’s milk powder. Plants like Waikato’s operate continuously, facing challenges such as wet weather and strict hygiene requirements while maintaining high output. Our evaporative condensers provide energy savings, ensure cleanliness, and enhance quality. New Zealand focuses heavily on exports, requiring top-quality dairy products for markets like China, Australia, and the Middle East. Our technology enables plants like Mr. Callum’s to increase milk production, boost profit margins, and improve customer satisfaction.
Overall, the project was a success. Mr. Callum is pleased, his team is motivated, and we are proud of our work. It demonstrates that our condensers are capable of meeting the rigorous demands of the dairy industry. Beyond milk, New Zealand has other sectors like meat and fruit that also require effective cooling solutions, and we are ready to assist them too.