Transforming Waste Heat into Savings at Gold-N-Plump

Transforming Waste Heat into Savings at Gold-N-Plump

by | Jan 30, 2011 | Projects

Rohde Brothers recently embarked on an ambitious project with Gold-N-Plump, a leader in the poultry industry. Our mission was to engineer a solution that turns waste heat from the ammonia cooling system into a valuable resource for the plant’s sanitation needs.

The Challenge: Gold-N-Plump needed an efficient way to heat water for production and sanitation. They turned to us to design a system that could harness the excess heat generated by their ammonia refrigeration system.

Innovative Custom Solution:

  1. Groundbreaking Heat Pump Design: We developed a custom-designed heat pump that is eight times larger than traditional models, setting a new standard in the industry.
  2. Efficient Heat Recovery: Our system directly recovers heat from the ammonia refrigeration system, an innovative approach to energy efficiency.
  3. Integrated Control Systems: We seamlessly integrated the hot water heating system controls with the ammonia refrigeration controls for optimal performance.
  4. Remote Monitoring: The inclusion of remote monitoring and data collection ensures continuous, efficient operation.
  5. Rapid Implementation: Our team designed, engineered, and implemented the system within just 6 months, coordinating closely with Gold-N-Plump to minimize disruption during scheduled plant shutdowns.
  6. Scaled for High Demand: The system was scaled to meet the plant’s significant daily use of 1,000,000 gallons of 140°F water.
  7. Record-Setting Achievement: This project boasts the largest heat pump heat recovery unit in Wisconsin.
  8. Impressive Savings: The system saves Gold-N-Plump $178,000 annually in energy costs.

Conclusion: This project is a milestone for both Rohde Brothers and Gold-N-Plump, demonstrating how innovative engineering can lead to significant energy savings and operational efficiency. We’re proud to have delivered a solution that not only meets Gold-N-Plump’s needs but also sets a new standard in industrial heat recovery. If your business is looking to turn waste into wealth, Rohde Brothers is ready to make it happen.

Waste Heat Recovery – Pond loop

Waste Heat Recovery – Pond loop

by | Jan 26, 2011 | Projects

Rohde Brothers Inc. Innovates with Custom Geothermal Pond Loop Systems

In the ever-evolving world of industrial heating and cooling, Rohde Brothers Inc. is breaking new ground with its cutting-edge geothermal pond loop systems. Leveraging the power of 3D modeling and Finite Element Analysis (FEA), we have successfully designed and installed a series of these systems, marking a significant leap in operational efficiency and cost-effectiveness.

Our latest project showcases a patent-pending, undersized pond system, ingeniously designed to eliminate the costly requirement of vertical wells typically associated with traditional geothermal systems. This innovative approach not only reduces the initial investment but also streamlines the installation process.

But that’s just the beginning. In a bold move, we’ve integrated process cooling loops with the geothermal loop. This unique combination allows for the beneficial reuse of waste process heat generated by air compressors, refrigeration compressors, and hydraulic systems. This repurposing of waste heat, utilized effectively with heat pumps, provides a triple advantage: comfort heating, sanitation, and process heating, thereby significantly reducing the reliance on conventional methods.

Further enhancing the system’s efficiency, the geothermal loop steps in to provide necessary cooling for any excess heat. This feature minimizes the need for additional cooling towers, again leading to substantial cost savings in both maintenance and operation.

Installation ease and efficiency have been a key focus in our design. The skid-mounted pump systems are pre-piped and pre-wired, complete with controls. This modular design drastically cuts down the cost and time associated with installation, allowing for a smoother, faster transition to operational status.

At the heart of the system’s operability is the web-based Honeywell Tridium control system. This advanced interface, working in conjunction with the Allen-Bradley PLC system, provides a user-friendly, graphical interface that allows easy monitoring and control of the entire system.

Rohde Brothers Inc. is proud to be at the forefront of innovative solutions in industrial plumbing, HVAC, and energy projects. Our geothermal pond loop systems are a testament to our commitment to delivering cost-effective, efficient, and environmentally friendly solutions to our clients. Stay tuned for more groundbreaking projects from our team!

Rohde Brothers Inc. – Innovating for a Sustainable Future.

Innovative Ammonia Refrigeration System Redesign at Grande Cheese

by | Jan 30, 2008 | Projects

At Rohde Brothers, we recently completed a challenging yet rewarding project for Grande Cheese – redesigning and implementing an expanded ammonia refrigeration system in just 7 ½ months. This project is a testament to our ability to deliver efficient, cost-effective solutions under tight timeframes.

Ammonia Cooling System PipingProject Overview: The task was to expand the existing ammonia refrigeration system while integrating advanced controls and maximizing the use of the existing infrastructure. Our team not only met but exceeded these requirements through innovative engineering and design.

Our Customized Solution:

  1. Efficient Design: We significantly reduced the ammonia charge in the system from 14,000 lbs to 7,000 lbs. This was achieved by eliminating the high-pressure receiver, a key aspect of our redesign.
  2. Advanced Technology Integration: We incorporated variable frequency drives on all components, including two new 150 HP compressors.
  3. Optimized for Seasonal Efficiency: The system was designed to operate at lower pressures during cooler months, enhancing efficiency and reducing costs.
  4. Redesign of Expansion Devices: Our redesign ensured that high pressure liquid wasn’t necessary for the evaporator coils, improving system safety and efficiency.
  5. Maintenance and Safety Improvements: By removing surge drums, we eliminated the need for frequent relief valve changes and simplified oil drainage in the ammonia room.
  6. Significant Cost Savings: The project resulted in over 38% savings in electrical costs and reduced gas costs by 5-10%. Maintenance and operating costs were also significantly lowered.
  7. Compliance and Additional Savings: Our redesign brought the system below EPA and OSHA thresholds, eliminating the need for a full Process Safety Management program and saving $30,000 in consulting fees.

Client Impact: Grande Cheese benefited greatly from our solution, not only in terms of system efficiency and safety but also through substantial cost reductions. The project’s success reflects our commitment to providing high-value, sustainable solutions to our clients.

Conclusion: This project with Grande Cheese showcases Rohde Brothers’ expertise in industrial refrigeration systems. We pride ourselves on delivering customized, efficient solutions that meet specific client needs while ensuring environmental and safety compliance. If you’re looking for a partner to upgrade or redesign your refrigeration system, Rohde Brothers is here to bring your project to life.

Pioneering HVAC and Process Solutions at Johnsonville Sausage’s Expansion Projects

by | Jan 30, 2007 | Projects

Process Piping for food manufacturingSince the early 1970s, Rohde Brothers has been a key partner in Johnsonville Sausage’s journey of growth and innovation. Our longstanding collaboration has spanned various projects, big and small, across their multi-plant meat processing campus.

Long-Term Partnership: Our relationship with Johnsonville Sausage’s engineering department is built on mutual trust and a deep understanding of their needs. We’ve been involved in everything from minor HVAC system adjustments to major installations and maintenance projects in process and wastewater treatment plants.

Highlight Project – The Meadowside Plant Expansion: A standout example of our collaboration is the Meadowside Plant Expansion. Here, we successfully completed the HVAC work for the 81,600 square foot expansion. This project included:

  1. Customized Ventilation Solutions: We designed and installed ventilation systems tailored for new custom cook equipment.
  2. Controls and Steam Piping: Our team expertly handled the installation of control systems and steam piping.
  3. Efficient Execution: Despite tight deadlines and the need to avoid disrupting ongoing operations, we delivered on time and beyond expectations.

Client Testimonial: Eric Grams, Senior Project Manager at Miron Construction Co., Inc., praises Rohde Brothers for our deep industry knowledge, ability to understand client needs, and proficiency in execution, leading to repeated collaborations on Johnsonville Sausage expansion projects.

Our Customized Solutions: Our work encompassed a variety of complex tasks, including:

  • Engineering and application problem-solving with effective trade coordination.
  • Unique solutions for process ventilation, steam, and gas service.
  • Installation of advanced HVAC systems, including controls and high-pressure steam piping.
  • Specialized ductwork in food production areas using heli-arc welded stainless steel.

Conclusion: At Rohde Brothers, our commitment to innovation and efficiency shines through in projects like the Johnsonville Sausage expansions. We take pride in delivering tailored solutions that meet and exceed our clients’ expectations. If your business seeks a partner for advanced industrial solutions, Rohde Brothers is ready to bring value and ingenuity to your projects.