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Excalibur improve refrigeration
efficiency at Cargill by 30%

Acquired by Cargill in 2008, Freeman’s of Newent are a primary chicken processing business,
supplying independent butchers and the retail food sector.

As part of their drive to improve energy efficiency the management
commissioned a site review to understand the opportunities to reduce
energy consumption.
The spiral refrigeration plant used to chill chickens prior to packing
and despatch was highlighted as a major energy user that should be
investigated.
The system comprises five large Sabroe reciprocating compressors,
operating on the R22 replacement refrigerant R417a, and provides
cooling for a line which processes 72,000 chickens a day.
Due to the site having a limited electrical supply, power for this area is
provided by 2 large oil fired generators.
Freeman’s approached Excalibur to investigate the possibilities of
improving the efficiency of this system. A detailed study and modelling
of the refrigeration system showed that there was potential to reduce
energy consumption by more than 30%.
Excalibur were contracted to undertake the proposed modifications
which included the installation of Liquid Pressure Amplification and
inverter control of condenser fans. This allows the compressors to be
re-commissioned to operate at low head pressure, reducing compressor
energy consumption and increasing refrigeration capacity.
The effects of the modification were immediate; production was increased
due to lower temperatures in the chiller, as a result of the LPA system
delivering better quality liquid refrigerant to the expansion valve.
Oil consumption for the generators, which provide the electrical supply
dropped by over 1000 litres / week, with the project achieving a return
on investment of 18 months, and an annual reduction in carbon emissions
of 150 tonnes.
Excalibur improve refrigeration
efficiency at Cargill by 30%
Acquired by Cargill in 2008, Freeman’s of Newent are a primary chicken processing business,
supplying independent butchers and the retail food sector.
_case study
Energy Efficient Management

As a result of this project our refrigeration in this area has been far more
reliable and the energy reduction has been inline with our expectations.

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