This Dairy Toolkit from Danfoss shown energy saving technologies and its application in dairy industries. It was used in the context of energy auditor training in Nepal in 2012 that was supported GIZ NEEP Programme.

1. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 1
Enery Savings
in Dairy Applications

2. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 2
Opportunities
• Milk Cooling at Collection centre
• Dairy Plant level
• Chilling centre level
• Cold Stores at Plant & Warehouse

3. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 3

4. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 4
Milk Cooling system

5. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 5
Replace the Piston Technology with Scroll

6. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 6
Recip v/s Scroll
Details Reciprocating Scroll
Displacement 100 70
COP / EER MODERATE - HIGH HIGH
Serviceability YES NO
Reverse Rotation No issue Need protection
Range … to 13.5 HP 1.5 to 30 HP
Liquid Handling capability
OK… within
compressor charge
limit
OK… within
compressor charge
limit
Applied cost MODERATE HIGH
System service / maintenance MODERATE CRITICAL
Pump down control
Scavenging pump
down allowed
Only static pump
down allowed
Sensitivity to load variations and working
conditions MODERATE HIGH

7. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 7
0,4
0,45
0,5
0,55
0,6
0,65
0,7
0,75
0,8
1 1,5 2 2,5 3 3,5 4 4,5 5 5,5 6 6,5 7 7,5 8
ISENTROPICEFFICIENCY
PRESSURE RATIO
Built-in pressure ratio
(geometrical)
(EXAMPLE)
In scroll compressors the isentropic efficiency depends on
the shape of the scrolls, that means on which pressure
difference it has been optimised.
Technologies specificities : Scrolls Vs. Recip
Optimization point :Scrolls Vs. Recip

8. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 8
Design
The refrigerant vapor is compressed by a piston
that is located inside a cylinder.
The piston is connected to the crankshaft by a
rod.
As the crankshaft rotates (by a motor), it causes
the piston to travel back and forth inside the
cylinder.
Suction valve and the discharge valve, are used
to trap the refrigerant vapor within the cylinder
during this process.
Compressors- Working Principle
Reciprocating Compressor

9. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 9
Design
It works on the principle of trapping the
refrigerant vapor and compressing it by
gradually shrinking the volume of the
refrigerant.
The scroll compressor uses two scroll to
perform this compression process.
The stationary scroll contains a discharge
port.
The driven scroll is connected to a motor by
a shaft and bearing assembly.
Compressors- Working Principle
Scroll Compressor

10. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 10
Reciprocating (Piston) v/s Scroll

11. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 11
Multiple Condensing Units

12. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 12
Heat Recovery from Condenser
The Cool New Way To Heat Water
Real power savings for every business using a
refrigeration plant and generating Hot Water.

13. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 13
Heat recovery
Up to 60% power savings – (AgResearch Field Tested
on a dairy farm application)
Can generate upto 85 Hot Water
Return on investment – From within 12-24 Months
(application dependent - Tariff - Volume of Hot water etc.)
No CO2 emissions

14. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 14
How does it look?

15. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 15
Heat Recovery from Condenser
REFRIGERATION & AIR CONDITIONING DIVISION April 2009
 Unitech visit – June 15th 2010
Special demand :Heat Recovery system
REFRIGERATION & AIR CONDITIONING DIVISION April 2009
 Unitech visit – June 15th 2010
Special demand :Heat Recovery system

16. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 16
Can be built on Condensing Unit
HeatRecovery
HeatRecovery

17. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 17
Some Practical Opportunities
• Ventilation
• Clean Condenser

18. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 18
Condensing Unit Installation
Allow Free Air Flow on CDU
Ensure good ventilation

19. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 19
Ensure GOOD ventilation
The Hot air should go out of the room and NOT recycle into the condenser.
RISK: Increase in Power bill, longer cooling time, shorter compressor life

20. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 20
Keep Condenser Clean
RISK: Shorter compressor life; high power bill; longer cooling time

21. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 21
RGE/XGE Fan speed regulators
Condenser Fan speed Regulation

22. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 22
DANFOSS VLT
®
YOUR PARTNER IN DAIRY

23. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 23
Fixed AC Input
(3ph,415v,50hz
)
Variable AC Output
( 0-415v,0-x Hz)
What is a Variable Frequency Drive ( VFD) ?

24. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 24
VFD APPLICATION
RESULT
Variable speed control:
•50% energy savings when
the fan or pump speed is
reduced from 100% to 80%

25. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 25
 Homogenisers (Control via. Flow or Level)
 Separators / Clarifiers (Speed Control)
 Silo Agitators (Control via. Level)
 Filtration Plants Pumps (Control via. Flow & / or
Pressure)
 Size range 1.1kW – 50kW
MILK Standardization – VFD applications

26. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 26
BUTTER Manufacturing – VFD Applications
• Silo Agitators (Control via. Level)
• Cream Pumps (Positive pumps) (Control
via. Level or Flow)
• Separators / Clarifiers (Speed Control)
• Butter churns
• Size range 1.1kW – 50kW

27. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 27
Cheese Manufacturing VFD Applications
• Transfer Lobe Pumps (Control via.
Level or Flow)
• Cheese Machine Drive Motors
• Rapid Cool Storage
• Stirrer Motors
• VSD Size Range 1.1kW – 90kW

28. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 28
• film movement control through
Danfoss MCO + Drives
• Sealing tool positioning
• Precise side roller movements for
continuous sealing of film
• VFD control for all motors
HFFS
• Precise film movement
coordinated with product drop
• Weigher synchronization with
Bagging machine
• Motor control by VFD for
vertical, weigher & roller assembly
VFFS
FOR HORIZONTAL
ROLLER
FOR CUT LENGTH
SEALING JAWS
FC 300
Series
MCO
MCO
FOR ROLL
UNWINDING
WEIGHER
CONTROL
PACKAGING

29. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 29
We Understand: NEED OF MODERN DAIRY
• Drives capable of operating under wash down conditions
• Compatible to CIP application, which is a standard for most
Dairy equipments
• Compact & optimum utilization of space
• Energy Savings operation
• High operational efficiency
• Drives which cover wider range of motor KW ratings
• Operation in high ambient temperature
• Higher uptime & service support
• Low set up & replacement cost

30. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 30
HOW CAN DANFOSS VLT DRIVES
BE YOUR PARTNER
TO REDUCE YOUR
OPERATING COST ??

31. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 31
OPERATIONAL EFFICIENCY
DAIRY
REQUIREMENT
DANFOSS VALUE
 Energy savings
operation
 Low transmission
losses
 Low initial cost of
drive (over
designing)
 Back channel cooling
translates to 5-10% savings
 Danfoss VLT drives do not
require output reactors<150
m cable length
 savings of 5% on output
choke of total project cost
 Reduces transmission losses
by 0.5% due to output
reactors
 No de rating required due to
50 deg.c rated temperature

32. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 32
OPERATIONAL EFFICIENCY
DAIRY REQUIREMENT DANFOSS VALUE
 Faster payback
period for critical
application
 Low heat loss
 With Danfoss drives
having less heat loss and
Highest Efficiency you can
achieve the same .
 Danfoss offers Savings
in lakhs /year on heat
loss against its
competitors

33. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 33
Innovative cooling
• Two cooling possibilities:
• Back cooling - Air ducted in
and out the back
• Duct work cooling - Air
ducted in the bottom – out
the top
• 85 % of the heat will not
enter control room – saves on
a/c
• Takes less space
• Cooling air for “power part” is
separated from the
electronics

34. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G
Upper exhaust
Back exhaust
Back inlet
Bottom
inlet
Heat sink fan
Heat sink
IP54 Seal
 Two cooling possibilities
 Back cooling –
Air ducted in and out the back
 Duct work cooling –
Air ducted in the bottom, out the top
 85% of the cooling air volume
never enters the controls area
 Separate path makes heat sink
cleaning easy
 Pre-engineered, thermally tested
cooling kits available
for Chassis enclosuresPower
component
cooling
Control
component
cooling
Innovative Cooling

35. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 35
VLT DRIVE IP66 CONSTRUCTION
DAIRY CONDITIONS DANFOSS VALUE
 Heavy water jets
 Continuous water
contact
 Heavy fouling condition
 Space constraints for
MCC & PCC panel in
plant
 IP 66 Drive from Danfoss is
ideally suited for heavy
wash down application
 IP 66 drive coated with strong
epoxy paint
 No SS Panel required for IP
54/66 rating drives
 Owing to 50 deg.c operating
temp & back channel cooling,
Danfoss drives are sized
optimally

36. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 36
BENEFIT TO DAIRY
DAIRY
REQUIREMENT
DANFOSS VALUE
 Compatibility to
third party
Automation / PLC
 Drives to operate
in corrosive
condition
 Drives covering
wider range of KW
ratings
 Danfoss drives interface with
device net /profi bus / Ethernet
and all universal bus protocols
 Danfoss drive with Special 3C3
coated PCB & casing with IP 66
ensures adaptation to harsh
rusting application
 Micro advanced – 0.18 to 22kW
 VLT 2800 – 0.37 to 18.5 KW
 FC 300 Series – 0.37 to 1.4 MW
 IP 66 enclosed – Up to 90KW

37. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 37
BENEFIT TO DAIRY
DAIRY REQUIREMENT DANFOSS VALUE
 Strong service
network, and
minimum time for
problem redress
 Spare parts
availability
 Specialists for
dairy equipments
 Danfoss has dedicated
regional service engineers
to provide service within 24
hrs.
 Danfoss maintains safety
stock which are delivered
24 hrs
 Danfoss has over 32
dedicated partners for
drives business nationwide
offering core expertise

38. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 38
DAIRY RANGE FROM DANFOSS
IP 66 Enclosed
VLT drives
 Range from 0.37 to 90KW
 All cast Aluminum parts with epoxy
coating.
 Unique cooling concept with no ambient
air flow over electronics
 All screws in SS
 Fan designed to withstand corrosion
FC 300 Series  Range from 0.25 kw to 1.4 MW
 Rugged drives ,Built in DC Chokes low
cost of ownership
 Built in 6 line Graphical Display with KWH
Meter
FC 300 series with MCO gives supreme
performance with accurate positioning

39. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 39
DAIRY RANGE FROM DANFOSS
VLT 2800  Range from 0.37 to 18.5KW
 Easy set up and low installation
cost , long life capacitor .
 Ease of repairing under
breakdown,
 Versatile drive covering all fan &
pump motor application typical
to dairy
Micro Advanced series  Range from 0.25 to 22 KW
 LCD Detachable display with copy
function
 Extremely rugged drives with
plug & play operation
 Economical solution

40. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 40
TOTAL SAVINGS
DANFOSS ADVANTAGE VALUE
 Inbuilt DC choke (% of drive cost) 15%
 Heat loss (certified) Vs competitor per year 15%
 Output reactor cost (% of project cost) 5%
 Back channel cooling (savings/year) 2%
 SS MCC panel cost (% of drive cost) 30%
 Over designing cost due to de rating at
higher temp of 50 deg.c as compared to
other makes
Initial cost of
higher rating
drive
Sample calculation for IP 66 90 KW Drive
CAN RESULT IN 2-3 Paise saving/litre of milk produced

41. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 41
DANFOSS ADVANTAGE
A Savings
of 20% on
the SS
panel cost
Heat loss
saving upto
35% in heat
dissipation
15%
savings on
inbuilt DC
choke
90% plant
uptime with
Danfoss
service
Rated
design
operating
temp. at
50deg.c
TRUST
DANFOSS

42. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 42
OEM SUPPORT
 Dedicated partner for drives in
separators, decanters, homogenizers
 Danfoss part of standard equipment
 products in line with their technology
 Inherent part of separators
manufactured
 Worldwide technology partner
 Other equipments include butter
churning, cleaning equipment
 Work closely to understand their
technology needs
 Joint up gradation of products
 strong application partners