Industrial Refrigeration & Compressor Systems

Challenge: Aemetis Biogas faced operational inefficiencies and high downtime costs at dairy digester sites due to unreliable compressors and lack of remote monitoring. Compressor issues impeded biogas conversion, risking $4,000–$9,000 in daily losses while requiring onsite troubleshooting.

Solution: Copeland's Vilter compression technology resolved these issues with industry-leading reliability and remote-control capabilities. The Vilter systems delivered over 98% uptime reliability at digesters and 99% at the RNG facility, enabling lower operational costs and scalability for future expansions.

Challenge: The Guidant John Rose Minnesota Oval needed a reliable, efficient ammonia refrigeration system to maintain 110,000 sq. ft. of world-class ice despite fluctuating temperatures. High capacity, optimal part-load efficiency and precise control were critical for consistent performance and safety. 

Solution: Copeland's Vilter single screw compressors provided 800 tons of cooling with unmatched reliability and efficiency. The dual slide design ensured precise capacity control and part-load optimization, enabling world-class ice quality while minimizing maintenance and operational costs. 

Challenge: A leading European food producer faced a variety of issues related to aging CO₂ compressors in its refrigeration system, with prolonged maintenance and unplanned downtime stalling production. Persistent oil carry-over issues and faulty capacity control hampered optimal performance and efficiency. 

Solution: Copeland’s Vilter CO₂ single screw compressor provided a reliable replacement, nearly doubling cooling capacity while reducing maintenance needs. The upgraded system enhanced reliability, performance and environmental sustainability, delivering over 1,500 runtime hours with greater efficiency. 

Challenge: The city of Drammen, Norway, sought a sustainable district heating solution using North Sea water. They required a system providing 194°F water with low operational costs and environmental impact, utilizing a non-ozone-depleting refrigerant with zero global warming potential. 

Solution: Copeland’s ammonia-based heat pump with Vilter single screw compressors achieved the city’s goals, offering 15% better efficiency than alternatives. This innovative system sustainably delivered high-temperature water, reduced reliance on fossil fuels and minimized maintenance needs. 

Challenge: Chile’s top poultry processor incurred high energy costs from relying on boilers to heat well water for sanitation while wasting heat from refrigeration. They sought an efficient, low-maintenance solution using a non-ozone-depleting refrigerant with zero global warming impact. 

Solution: Copeland's ammonia heat pump system repurposed waste heat from refrigeration to heat 350 gallons of water per minute, reducing energy costs by 72% and saving 15 million gallons of water annually. This eco-friendly solution also minimized maintenance while ensuring outstanding efficiency. 

Challenge: An auto parts manufacturer in Chachoengsao, Thailand, relied on liquid petroleum gas boilers for heating, facing high energy costs and safety risks. The factory required a reliable, efficient solution to consistently supply 72-73°C water for its production process.

Solution: Switching to heat pumps powered by Copeland ZW KB compressors halved their energy bills and enhanced plant safety by eliminating high-pressure boilers. This upgrade delivered consistent, efficient water heating, showcasing a significant improvement in cost and operational reliability. 

Challenge: A pharmaceutical plant in China relied on traditional energy sources for water heating, office space heating/cooling and steam pressure needs, leading to high energy use and emissions. The facility faced sustainability challenges and sought a solution to reduce environmental impact and costs.

Solution: Copeland’s air-sourced heat pumps replaced traditional sources, cutting electrical energy use by 50% and reducing emissions by 5,813 tons of CO₂, 54 tons of SO₂ and 165 tons of hydronitrogen annually. This upgrade delivered efficient heating and cooling with significant environmental benefits.