Project:
Sara Lee, Suffolk, Virginia
The Challenge:
Sara Lee Coffee & Tea, North America has one of two liquid coffee production facilities in the world – the second one is located in the Netherlands. For its construction in Suffolk, the client hired ColonialWebb Contractors to design and install a complete refrigeration, cooling and storage system.
Our engineering department developed safety and management plans and operating procedures. The electrical department supplied and installed the wiring, controls and specialty accessories.
Our Approach:
The refrigeration system is comprised of:
- Frick screw compressors
- Pressure vessels
- Ammonia liquid recirculation packages
- Computerized controls
- Piping that produces more than 900HP of refrigeration
The refrigeration system will blast freeze products at -40 degrees then will maintain them at -4 degrees in a holding freezer. Loading and shipping docks are controlled at 41 degrees and 50 percent RH.
ColonialWebb designed and installed a computerized control system to manage temperature and humidity conditions. The central control device is an Allen Bradley microprocessor that supervises and regulates the system, which is accessible through the plant’s local area network, modem or Internet.
This process cooling system uses:
- Two Trane 500-ton screw chillers
- Three fluid coolers
- Three plate and frame heat exchangers
- Seven pumps
- Stainless steel piping and control valves
We also supplied refrigerated hygienic warehouse and blast freezer enclosures, under-floor insulation, and doors.
ColonialWebb fulfilled this major contract by providing a quality product as well as being ahead of schedule and under budget. We also will provide ongoing service and mechanical support for the facility.