Refrigeration typically accounts for more than 40% of electricity consumption in dairy processing, making cooling system efficiency one of the biggest influences on operating costs. Yet while investment is often focused on refrigeration plant and production equipment, the condition of the cooling system itself is frequently overlooked.

Hydratech works in partnership with many of the UK's leading dairy processors—including Arla, Müller, Saputo and Rodda's—to improve cooling system efficiency, reliability and long-term performance. Combining engineering expertise, advanced heat transfer fluids and specialist Fluid & Systems Management (FSM) services, Hydratech helps operators reduce energy consumption, increase productivity and minimise unplanned downtime.

At a Glance

Industry
Dairy Processing
Customers
Leading UK dairy processors including Arla, Müller, Saputo & Rodda's
Challenge
Declining cooling performance, rising energy consumption and system contamination
Hydratech Solution
Engineering expertise, Coolflow DTX™®, Fluid Monitoring Program (FMP) and ongoing system optimisation
Result
17% reduction in cooling energy consumption

The Challenge

Refrigeration is one of the largest consumers of electricity within a dairy processing plant. As cooling systems age and production demands evolve, hidden issues can gradually reduce efficiency, increase operating costs and affect long-term reliability.

Hydratech works alongside dairy processors to identify and resolve these issues before they impact productivity, helping customers improve cooling system performance through engineering expertise, advanced heat transfer fluids and proactive system management.

Common Issues We Identify

Across dairy processing plants, Hydratech regularly identifies issues including:

  • Fluid degradation
  • Process contamination
  • Reduced heat transfer efficiency
  • Increased pumping energy
  • Corrosion
  • Biological fouling
  • Hydraulic inefficiencies
  • Higher operating costs
  • Increased maintenance requirements

Left untreated, these issues gradually reduce cooling system performance while increasing energy consumption and operational risk.

Customer Success Story

Significant Reduction in Cooling Energy Consumption

A major UK dairy approached Hydratech following concerns around declining cooling system performance and increasing energy consumption.

Following Hydratech's on-site sampling and comprehensive in-house laboratory testing, a number of issues affecting cooling system performance were identified, including:

  • Milk fat contamination within the chilled water system
  • Degrading glycol condition
  • Reduced heat transfer efficiency
  • Hydraulic inefficiencies
  • Increased refrigeration load

Hydratech used these findings to develop a targeted programme of remedial works, engineering improvements and an upgrade to Coolflow DTX™® to optimise cooling system performance, improve reliability and reduce energy consumption.

  • The programme included:
  • Comprehensive fluid analysis
  • Bespoke research and development
  • Removal of process contaminants
  • Cooling system modifications to improve hydraulic performance
  • Upgrade to Coolflow DTX™®
  • Ongoing Fluid Monitoring Program (FMP)
  • Planned Preventative Maintenance (PPM)

The Results


 

Following completion of the programme, the dairy reported:

  • 17% reduction in energy consumed by coolant circulation pumps and process cooling systems
  • Reduced refrigeration compressor loading
  • Shorter compressor running times
  • Improved cooling system performance
  • Increased operational reliability
  • Extended equipment life

To preserve these gains, the dairy now benefits from an ongoing Planned Preventative Maintenance programme delivered by Hydratech's Fluid & Systems Management team.

More Than Heat Transfer Fluids

Hydratech is more than a manufacturer of heat transfer fluids.

Through its dedicated Services Division, the company combines chemical engineering, mechanical engineering and practical site expertise to help customers improve cooling system performance throughout the operational life of their systems.

Its integrated approach combines:

• Engineering expertise

• Advanced heat transfer fluids

• Fluid Monitoring Program (FMP)

• Cooling system optimisation

• Commissioning and recommissioning

• Corrosion and water chemistry management

• Biological monitoring and remediation

• Planned Preventative Maintenance

• Ongoing engineering support

Together, these services help dairy processors reduce operating costs, improve reliability and maximise cooling system performance.

Could Your Cooling System Perform Better?

Many cooling system issues remain hidden until they begin affecting productivity, energy consumption and equipment reliability.

Hydratech's Fluid Monitoring Program (FMP) combines on-site sampling, comprehensive in-house laboratory testing and engineering expertise to identify hidden issues before they become costly failures.

Whether you're looking to reduce energy consumption, improve reliability or extend equipment life, Hydratech can help optimise the performance of your cooling system.

Reduce Energy Consumption. Improve Reliability. Protect Productivity.

Contact Hydratech today to arrange a Fluid Monitoring Program assessment and discover how your cooling system could perform better.