Nestle's coffee production

Planning / Implementation / Main components

Star Refrigeration Ltd.

Refrigerant

ammonia (NH₃) / secondary refrigerant carbon dioxide (CO₂)

System start-up

2000/2001

Nestle UK has been producing chocolate since 1913, and more recently coffee, including the world famous Nescafe brand, in Hayes, Middlesex. In order to comply with environmental standards the refrigeration plant was to be upgraded.

Demands

The freeze drying line was installed in the 1960's and used the greenhouse gas R22. Additional challenges were posed by the existing production lines and the traditional style of the art deco building.

Solution

A large, low temperature industrial refrigeration system has been commissioned using a cascade between ammonia and carbon dioxide as the working fluids in the plant.

Type of facility

NH₃ / CO₂ cascade refrigeration plant

Refrigerant

NH₃

Refrigerant volume

5,000 kg

Refrigerant

CO₂

Refrigerant volume

20,000 kg

No. of refrigeration compressors

four NH3, four CO₂

Refrigerant temperature

2 low temperature levels at -48 °C and -54 °C, small side load at -16 °C

Refrigerating capacity

2,400 kW

Main components

CO₂ pump sets, condenser, receiver, Ammonia plant

Special features / Comments

The pipework is all stainless steel which gives some benefits in corrosion resistance but more important ensures the high strength of the pipes at low temperatures.