Challenges of HVAC installations in industrial facilities – the example of the “EL Grito” factory
At Alfa Therm, we design HVAC systems for various purposes on a daily basis, from commercial spaces to demanding industrial operations. Each project has its own specifics, but the common base of all solutions is the customer and technological process adaptation. That is why at the beginning of each project, we pay special attention to defining the project task in cooperation with the investor and the main technologist. It is it possible to design installations that are functional, reliable and optimally integrated into the one unit, only when the requirements of the production process are clearly defined.
Food Industry Requirements
The food industry is one of the most complex branches of the process industry, with emphasized hygiene standards and strictly defined thermal, energy and ventilation needs. Such operations require a large number of mechanical installations, and each project is extremely specific.
Characteristics of food processing plants are:
- high energy consumption (steam, gas, compressed air, hot and cold water)
- different temperature regimes
- strict control of air quality and ventilation
- continuous operation of HVAC system without the possibility of long downtime
- frequent need for phased construction and future extensions
Because of all of the above things, there are almost never two identical industrial projects, which requires a high level of flexibility in design.
Example: Tortilla and tortilla chips factory “EL Grito”
One of such projects is the new factory “EL Grito” in Orašje, an investment of the company UNION FOODS d.o.o. Alfa Therm has carried out the entire mechanical thermotechnical installations according to the “design & build” principle, including design, implementation, automation and commissioning.
There are several elements that make this project specific:
- production technology ordered from the USA, without analogue plants in the region
- investment of more than 40 million euros
- phased development, where part of the line is installed immediately, and part is planned for future capacities
All this further emphasized the importance of precise planning, mutual coordination of installations and the possibility of later expansion.
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A boiler room – the heart of the process
The production of tortillas and chips requires a large amount of dry saturated steam, which is one of the key elements of the entire operation. That’s why the following has been designed and installed:
- steam boiler with a capacity of 2000 kg/h, working pressure 6 bar (≈160 °C)
- feed tank, condensate tank and associated pumps
- Water Treatment System and Safety Fittings
- pipeline distribution to the consumer carried out according to the technological schedule
During the design, the possibility of simple installation of an additional boiler has been left to support the increase in production capacity.
Compressed air installation
Compressed air plays an extremely important role in this factory, as it drives many elements of technological equipment. Due to the high and continuous air consumption of 7 bar pressure, a modern compressor station has been designed that contains:
- three rotary screw compressors (frequency regulated + working + spare)
- refrigeration dryer, tank and complete set of filters
- stainless steel (INOX) switchgear
The system is further optimised by using an oil-to-water heat exchanger, which uses the waste heat of the compressor to produce hot water, significantly increasing energy efficiency.
Liquefied petroleum gas (LPG) plant – a safe and stable source of energy
Regarding to the high gas consumption in the technological process, it was necessary to install a complete liquefied petroleum gas plant with multiple tanks, evaporators and complete regulation. The installation includes:
- four LPG tanks with a volume of 10 m³
- Gas evaporators
- regulation and safety equipment
- Complete gas pipeline to technological consumers
The system has been designed to ensure a stable and safe gas supply without interruption of operation.
Heating, cooling and ventilation of office spaces
In addition to the industrial part of the building, the administrative premises also received a modern HVAC system, which was designed as a highly energy-efficient system. The combination of heat pumps, gas condensing boiler and efficient recuperators ensures a stable temperature and air quality all year round.
Hot and cold drinking water preparation
Food production requires large quantities of hot water at different temperatures (55 °C and 80 °C), so large tanks heated by combined energy have been installed: compressor waste heat and gas boilers.
The engine room is equipped with:
- hot water tanks with a total capacity of 7500 liters
- heating system using the heat of compressors and gas boilers
- cooling units with a capacity of about 50 kW that provide water at a temperature of 4 °C
This part of the system is particularly sensitive because it has to meet technological requirements in terms of hygiene and temperature stability.
Automatic control as the brain of the entire system
In order for all these systems to work in a coordinated manner and without downtime, Siemens automation that controls the entire plant has been implemented. This enables:
- monitoring of all key
- parametersoptimization of equipment operation
- fast detection and elimination of deviations
- easy management for operators
Automation forms the central “monitoring brain” of the drive and enables a high level of reliability.
The project of the “EL Grito” factory shows how complex, but at the same time very efficient it is to design HVAC installations that are fully adapted to a specific technological process. Our team has completed every single phase, from design to commissioning, and contributed to the construction of a modern production facility that employs more than 40 people and uses domestic raw materials.
This project once again confirms that professional cooperation between designers, technologists and investors is key to creating systems that are reliable, energy-efficient and ready for future expansions.
