INCORPORATING COLD CHAIN
PROJECT
“ An increased footprint has allowed the facility to access new markets both in South Africa and Internationally . The abattoir has undergone significant upgrades to conform to national and international market requirements . Higher volumes have required investment in slaughter equipment , processing lines and most importantly , refrigeration .
East London Abattoir has FSSC 22000 accreditation , as international hygiene accreditation is required by corporate and international clients and is halaal-approved by South African National Halaal Authority and the National Independent Halaal Trust ,” says Glen Page .
During 2021 the owners of East London Abattoir decided they would like to expand their pork processing capacity . This was to include a new facility complete with slaughter lines , carcass chillers , processing hall and carton freezer . Due to the site layout and limitations in terms of capacity on the old ammonia plant , the owners opted for a new independent ammonia plant near the old facility .
Having experience with the robust nature and efficiency of ammonia systems with Grasso compressors , it was a natural choice to start discussions with GEA . The latter were selected for the project based on their ability to meet the compliance and safety standards of SANS 10147 for refrigeration systems , among other reasons .
SYSTEM CONFIGURATION
“ One of the project constraints was the limited power supply to the facility . Our primary objective was to provide East London Abattoir with the most efficient plant possible ,” commented Shaun Kelb ( head of project sales : refrigeration systems ). The refrigeration system was designed to operate as a compound ( two stage ) system at -40 o C / -5 o C /+ 32 o C .
The high stage load primarily consists of three carcass chillers that are designed for a throughput of approximately 600 pigs ( each at 95kg ) per day . An ammonia-to-glycol heat exchanger supplies chilled glycol to an air handling unit that maintains the deboning hall at the required optimal temperature .
The processed meat from the deboning hall is transferred directly into a carton freezer . The carton freezer is designed for 4 000kg / h (± 400 kWR @ -38 o C ) and was supplied and installed by Albrecht Machinery . The carton freezer was a significant improvement in terms of product quality and throughput as opposed to the make-shift containerised blast freezers that were used on site in the past .
The carton freezer control valve assemblies included GEA AWP isolating , pressure-relief and butterfly valves . To comply with SANS 10147 and prevent hydraulic locks , the required pressurerelief valves were fitted on the carton freezer valve assemblies . The installation included a standard GEA installation which incorporated controls for soft defrosting .
East London Abattoir ammonia plant room showcasing Grasso V-Series compressors .
largest VSD operating range , therefore providing optimal efficiency also in part load . East London Abattoir is our first installation of the Grasso VH-series in South Africa with operating speeds ranging from 500 – 1 500rpm .
For complete system control , a GEA Omni System Panel was installed . While the Omni panel has been in use for many years as a compressor and plant controller , its expanded functionality was used to include the control of the valve assemblies and all equipment connected to the refrigeration system at East London Abattoir .
The Omni system controller controls the capacity and sequencing of the compressors , evaporative condensers , monitors the pressure and liquid levels in the vessels , temperature control and defrosting of the carcass chillers , defrosting of the carton freezer as well as the heat recovery system .
The configuration of the new carcass chillers installed at East London Abattoir differs somewhat to that of standard carcass chillers in South Africa .
Schematic of an AU cooler installation .
Part of the existing building had to be demolished and the site cleared for the new abattoir .
GROUND-BREAKING TECHNOLOGY
Kleb explains many of the unique and first time used features of the ELA installation . “ The client opted for the reliable Grasso V-HSeries reciprocating compressors which have the highest efficiency and the
Air flow in the carcass chiller is of a unique design .
The electrical control room has a schematic of the plant with indicating LEDs .
COLD LINK AFRICA • January / February 2024 www . coldlinkafrica . co . za 21