1. Project Overview
This project involved the design, manufacture, and installation of a process glycol chilled water system for a well-known dairy brand to support the cooling of whey protein prior to onward transportation to a secondary processing facility. The objective of the system was to reduce the product temperature to 3 °C, ensuring product stability, quality preservation, and compliance with food processing standards during transfer.
IMD Process were selected as the system integrator responsible for the complete turnkey delivery, including:
- Process design and engineering
- Mechanical fabrication
- Electrical control system design and manufacture
- On-site installation and commissioning
The installed system provides a reliable and hygienic cooling solution designed for continuous operation within a dairy processing environment.
2. Process Requirement
During whey protein production, the product exits upstream processing stages at elevated temperatures unsuitable for storage or transfer. To maintain protein integrity and microbiological stability, the product temperature must be rapidly reduced to 3 °C.
The cooling solution therefore required:
- Rapid and consistent heat removal
- Hygienic design compatible with food processing standards
- Redundancy to ensure operational reliability
- Integration with existing plant utilities and infrastructure
A glycol-based chilled water system was selected due to its stability, freeze protection, and efficient heat transfer performance.
3. System Design
The cooling system utilises a glycol chilled water loop to extract heat from the whey protein process stream via heat exchangers.
Key Design Elements
- Stainless steel process buffer tank
- Multiple centrifugal circulation pumps
- Food-grade stainless steel pipework
- Automated control and monitoring system
- Temperature and flow instrumentation
The system operates by circulating chilled glycol-water mixture through the cooling circuit where heat is absorbed from the whey protein process stream.
4. Mechanical Design and Fabrication
The mechanical system was fabricated by IMD Process using hygienic stainless steel construction suitable for dairy processing environments.
Major mechanical components include:
Process Glycol Tank
- Fabricated stainless steel vessel acting as the chilled glycol buffer
- Provides thermal stability and system volume
- Designed for hygienic cleaning and durability
Pump Set
- Multiple centrifugal process pumps arranged in parallel
- Provides redundancy and scalable flow capacity
- Stainless steel process pipework designed to minimise pressure loss
Pipework System
- Hygienic stainless steel piping with orbital welded joints
- Designed to optimise flow characteristics and prevent contamination
- Insulated where necessary to maintain temperature stability
The system shown includes a four-pump circulation arrangement, allowing operational flexibility such as duty/standby configurations and staged capacity control.
5. Electrical and Control System
IMD Process also delivered the electrical and automation package, including:
- Stainless steel control panel enclosure
- Motor protection and starters for pump operation
- Emergency stop and safety isolation
- Integration of temperature and flow sensors
- Automated control logic for pump sequencing
The control system enables:
- Temperature monitoring and regulation
- Pump duty rotation
- Fault detection and alarm management
- Safe system shutdown if required
This automation ensures consistent cooling performance and energy-efficient operation.
6. Installation and Site Integration
The equipment was installed on-site at the facility by IMD Process engineers.
Installation activities included:
- Positioning and securing the glycol tank
- Mechanical installation of pumps and pipework
- Electrical installation and cabling
- Integration with plant utilities and existing systems
- Testing and commissioning
The compact installation layout ensures easy maintenance access while maximising plant space efficiency.
7. Operational Performance
Once commissioned, the system successfully achieved the project objective of cooling whey protein to 3 °C prior to transfer.
Key operational benefits include:
- Stable product temperature control
- Reliable pump redundancy
- Hygienic design suitable for dairy environments
- Efficient thermal performance
- Ease of maintenance and service access
The glycol cooling system provides a robust solution that supports continuous dairy processing operations and ensures product quality during transportation to the downstream facility.
8. Conclusion
The glycol chilled water system delivered for the client demonstrates a successful end-to-end engineering solution, combining process design, mechanical fabrication, electrical integration, and installation.
Through the expertise of IMD Process, the project provides a high-reliability cooling infrastructure capable of maintaining whey protein at 3 °C, safeguarding product quality and enabling efficient transfer to the next stage of production.
