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– not only the HVAC but also major maintenance on process equipment,” Magnus explained.
During this window:
• All textile and stainless steel ducting was installed
• The new AHUs were connected and tested
• Zoning was redefined with new dampers, sensors and controls
• The refrigeration plant room was simultaneously completed to provide chilled and hot water for the AHUs project
Outside the facility, work began even earlier. A new plant room was constructed on what had previously been a grass patch. Built on raft foundations due to dolomitic soil conditions, it housed the compressors, adiabatic condensers and piping headers feeding the HVAC system.
Rain added complications.“ It was rainy season when they wanted to construct the plant room. Twice it became a dam. Despite delays, the building was ready by the time the threemonth shutdown began,” Magnus recalled.
Unlike standard industrial projects, commissioning in a pharmaceutical-spec facility carries extra hurdles. Access is tightly controlled, with staff required to wear full-body PPE( Personal Protection Equipment) suits, boots and hoods before entering sensitive zones. This was to be avoided except in dire need.
“ We did what I call‘ live commissioning. As production started up again, we were still fine-tuning the system, with almost no access inside anymore,’” said Magnus.
Temperature and humidity probes had to be validated, airflow balanced and pressure cascades confirmed – all while Lactalis’ production lines for infant milk powder resumed operation. This overlap required not only technical skill, but also co-ordination with Lactalis’ international project managers.
Stainless steel pipe cladding for pristine conditions throughout the facility.
THE AIR SYSTEM SUPPORTING REFRIGERATION As refrigeration was the headline feature, the HVAC upgrade played a critical supporting role in enabling the former.
Key elements included:
• A new ammonia plant with a critical charge system, designed for efficiency and safety.
• GEA Grasso V series compressors for the lowest total cost of ownership( energy, maintenance and reliability)
• Heat recovery integration with the client’ s UHT process, reclaiming waste heat for hot water production.
• Adiabatic condensers, selected for water-saving benefits in South Africa’ s water-scarce environment.
By using natural refrigerant ammonia( with zero ozone depletion potential and zero global warming potential), the system aligned with Lactalis’ global sustainability strategy. Future-proofing was another cornerstone of the project. The refrigeration and HVAC systems were deliberately oversized by 50 %, creating headroom for growth.
RACA Journal I May 2026
A patch of green virgin ground was excavated and strengthened for the foundation of the new plant room
Currently, some Freon-based systems remain in service for older process loads, but the vision is: as Lactalis expands production at Clayville, these will be phased out and the ammonia plant will assume full responsibility.
The HVAC infrastructure, meanwhile, is already equipped to handle that expansion – ensuring that as output grows, air quality standards remain uncompromised.
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