DJ-Series Air Coolers for Ammonia Refrigeration System Upgrade in Dairy Plant

Project Overview

A dairy processing facility in Central Asia was upgrading its ammonia refrigeration system from aging R22 equipment. The upgrade required new evaporator units compatible with the ammonia (R717) system while maintaining uninterrupted production during the phased installation.

Challenge

• Existing R22 evaporators not compatible with ammonia — complete replacement needed
• Production downtime limited to 48-hour windows per zone during installation
• Dairy hygiene standards require stainless steel construction and easy-clean surfaces
• Extreme continental climate: summer ambient 40°C, winter -30°C

Our Solution

Hicool supplied 8 DJ-series heavy-duty air coolers from the WKDL product line, specifically configured for dairy applications:

• 8× DJ-150 units — stainless steel casing and drain pans (SUS304)
• Hot gas defrost system for rapid defrost cycles (critical for dairy hygiene)
• 12mm fin spacing to prevent ice bridging in high-humidity production areas
• EC fan motors for energy efficiency (30% less power vs. AC motors)
• All copper tubes internally cleaned and nitrogen-sealed for ammonia service

Technical drawings and connection details were provided 5 days after order confirmation, allowing the plant's installation team to pre-fabricate piping headers before the evaporators arrived.

Results

• 18-day delivery — all 8 units shipped in one batch
• Phased installation completed with zero production stoppages exceeding the 48-hour window
• Energy consumption reduced 25% compared to old R22 system
• All units running continuously for 8+ months with no issues reported

Key Takeaway

Refrigerant system upgrades (R22 to NH3) require more than just swapping evaporators — material compatibility, defrost method, and installation sequencing all must be carefully planned. Hicool's technical support covers not just equipment supply but also system integration guidance.