No Slide Title · SCROLL COMPRESSORS Nov 2007 ... • Ideally should have Air Compressor for even...

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John O’Keeffe

Moorepark on 13th NovemberMoate on 14th NovemberKildalton on 15th November

1

WHY COOL MILKWHY COOL MILK?? Nov 2007Nov 2007

• TO INHIBIT BACTERIAL GROWTH

• TO EXTEND STORAGE ON THE FARM

• TO REDUCE TRANSPORT COSTS

COOL TO:

6C for ED COLLECTION

4C for E2D COLLECTION

3C for E3D COLLECTION

2

Bacteria Growth in Milk Bacteria Growth in Milk Nov 2007Nov 2007

3

Effects of Time and TemperatureEffects of Time and Temperatureon Bacteria Growth in farm milk on Bacteria Growth in farm milk Nov 2007Nov 2007

Starting TBC of 5,000.

Milk Storage Expected TBC after storage forTemp [C] 2 days 3 days 4 days

2 5,000 15,000 50,000

4 10,000 30,000 100,000

6 30,000 100,000 1,000,000

Dilution effects of milking additions may be offset

by blend temperature increases during milking.

Cooling to 2C technically difficult.

For extended storage:• Fast cooling rate ie avoid high blend temps• Accurate temp control during storage [3 to 4C]• Excellent hygiene from teat to tank• Low SCC

4

BULK TANK MAKES BULK TANK MAKES Nov 2007Nov 2007

5

BULK TANK CONSTRUCTION BULK TANK CONSTRUCTION Nov 2007Nov 2007

USUALLY ALL STAINLESS STEEL

GRADE: At least equivalent to X5 Cr Ni 18-10 1.4301

as defined in EN 10088-2 :1995[304 to ISO683/X111

COMPOSITION:18% Chromium, 8% Nickel, 0.06% Carbon

• Easy to clean• Excellent appearance• Easy to fabricate• Good corrosion resistance

INSULATIONMilk Temperature rise <1C per 4Hrs

• Cork• Expanded Polystyrene• Polyurethane foam

Adheres to S.S.Makes rigid structure

6

BASIC REFRIGERATION SYSTEMBASIC REFRIGERATION SYSTEM Nov 2007Nov 2007

Compressor

Expansion Valve

Low Pressure High Pressure

Evaporator

Condeser

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CONDENSING UNITS CONDENSING UNITS Nov 2007Nov 2007

HERMETICCopelandManeuropL’Unite HermetiqueAspera

SCROLLCopelandYork/Bristol

Semi -hermetic Prestcold,Copeland,DorrinOpen Bitzer, Frigidaire.

E-Star HiPerForm®

Condensing Unit =Compressor + Air Cooled Condenser

OnOlder Tanks

8

SCROLL COMPRESSORS SCROLL COMPRESSORS Nov 2007Nov 2007

Notes on Scrolls:Notes on Scrolls:

One Scroll is static, the other is orbiting [moving] at 3000 RPM

3 moving parts [15 moving parts in reciprocating compressor]

Suction is on outside, Discharge is in middle.

Compression is a continuous process [squeezing]

Electric motor is an interference fit in shell.

Light in weight but high [slightly unbalanced]

No oil pump required

Crankcase heater required

• SCROLL TECHNOLOGY DEVELOPED BY FRENCH IN 1905

• M/Cs NOT AVAILBLE TO MANUFACTUREIT AT THAT TIME

• TECHNOLOGY RESURRECTED IN LATE 70’s

• MILLIONS OF SCROLLS NOW IN OPERATION

9

DIRECT EXPANSION DIRECT EXPANSION Nov 2007Nov 2007

COOLS MILK DIRECTLY BY REFRIGERANT

• Condensing unit must be capable ofcooling milk in specified time

• Good Electrical Supply needed• High Cooling Efficiency

up to 75 L/kWh• Condensing Unit works harder than in IB• Risk of milk freezing.

SMALL VOLUMES OF MILK

• Cooling to 3C – usually no problem• Cooling to 2C – Freezing will probably occur.

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ENCLOSED DIRECTEXPANSION ENCLOSED DIRECTEXPANSION Nov 2007Nov 2007

Evaporator [Cooling Pad] Condensing Unit

11

ICEICE--BANK / CHILLED WATER BANK / CHILLED WATER Nov 2007Nov 2007

MILK COOLED by CHILLED WATER from MELTING ICE

TYPES:• Sump and Spray• Jacketed• Separate Ice Builder

• CONDENSING UNIT:Smaller than on DX TanksBuilds ice over long periodCan be locked out during milk cooling

• LESS EFFICIENT THAN DX50L/kWhCooling cost similar if using Nightsaver

• FASTER COOLING• INSTANT IN-LINE COOLING

POSSIBLE• NO MILK FREEZING

12

ICEICE--BANK / CHILLED WATER BANK / CHILLED WATER Nov 2007Nov 2007

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ENCLOSED CHILLED WATER ENCLOSED CHILLED WATER Nov 2007Nov 2007

INSTANT COLINGINSTANT COLING

ICEBUILDER

PLATECOOLER

ENC CHILLED WATERTANK

14

ICEBUILDERS ICEBUILDERS Nov 2007Nov 2007

ALL ICEBUILDERS:

• Should be fully insulated

• Should have Summer/Winter Icebuilding positions

• Should have Expansion Valve control

• Should be fitted with High and Low Pressure Control Switches

• Ideally should have Air Compressorfor even ice melting

In all Instant Cooling Systems all Chilled Water Pipes should be fully insulated

15

MILK COOLING MILK COOLING EQUIPMENTEQUIPMENTNovNov 20072007

Ice Builder

Milk Tank

Milk Tank

16

ICEBUILDERS ICEBUILDERS Nov 2007Nov 2007

17

TANKS LOCATED OUTSIDE DAIRY TANKS LOCATED OUTSIDE DAIRY Nov 2007Nov 2007

Silo is an option

Manufacturers are also modifying Standard Bulk Tanks for use outside

If positioning tank outside:

Put down solid base on good foundation and make it bigger than tank.

Put protection railing around tank

Protect Agitator motor with cowl

Put all electrical control panels in a lockable sealedcabinet outside or inside

All vents should be lockable

Insulate and protect all Chilled Water pipes

Insulate and protect pipes to washer

18

SILO PLACED OUTSIDE SILO PLACED OUTSIDE Nov 2007Nov 2007

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SILO PLACED OUTSIDE SILO PLACED OUTSIDE Nov 2007Nov 2007

21

REFRIGERANTS REFRIGERANTS Nov 2007Nov 2007

R12R12• On all tanks pre-1980• None produced for a number of years as it:

Damages Ozone LayerDamages Ozone LayerContribute to Global WarmingContribute to Global Warming

• R134a is a replacement used on very few Bulk Tanks.• Convert to R404a if tank can take higher pressures

R22R22• Widely used Refrigerant - on most Bulk Tanks from

1980 onwards.• Cannot be used on new installations.• Available for service for life of existing installations• System on R22 can be converted to R404a but oil

must be changed a few times and also some control changes.• Advice is continue with R22 in system

R134aR134a• Introduced as replacement for R12• Used in fridges but in very few Bulk Tanks

R404aR404a R143a [52%] + R125 [44%] + R134a[4%]R143a [52%] + R125 [44%] + R134a[4%]

• Used on nearly all new Bulk Tank installations• Causes no Ozone Depletion and very little Global Warming.• Works well on Bulk Tanks

R507 R125 [50%] + R143a [50%]

• Used on some new Bulk Tanks [mainly Mueller]• Similar to R404a – slightly higher outputs 1.03

22

BULK TANK AGITATION BULK TANK AGITATION Nov 2007Nov 2007

Capable of dispersing fat evenly

No damage to membrane

Intermittent agitation

Accurate milk sample.Fat content of samples should not differ by more than 0.1g of fat per 100g of milk

No butter or froth formation

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ESB CHARGES ESB CHARGES Nov 2007Nov 2007

Day Units Day Units 16.1 c/ kWh16.1 c/ kWh [Unit] [Unit]

Night Units Night Units 8.00 c/kWh 8.00 c/kWh [Unit] [Unit]

Additional Charges for NightsaverOnce Off connection fee [from Jan 2007] : = €255Also €6.20/2Months extra Standing Charge

ie€37.23/AnnumA farmer with 50 cows , using 25% energy on Night units A farmer with 50 cows , using 25% energy on Night units could take up to 3 years to break even could take up to 3 years to break even ––after paying initial after paying initial installation fee.installation fee.

If already installed you need to use at least 15% of energy If already installed you need to use at least 15% of energy on Night units. on Night units.

Nightsaver is from 11.00PM to 8.00AM GMTie 11.00 PM to 8.00 AM in Winter

12 midnight to 9.00 AM in Summer

Domestic Rural Nightsaver

Domestic Rural

General Units General Units 15.0 c/ kWh15.0 c/ kWh [Unit] [Unit]

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MILK COOLING COSTSMILK COOLING COSTS Nov 2007Nov 2007

LITRES COOLED per kWhLITRES COOLED per kWh [Gals]to 4C to 3C

DX 75 [16.5] 68 [15.0]

IB 50 [11] 45 [10]

Using Domestic Rural rateUsing Domestic Rural rateCost Cost €€ per 4500 Litresper 4500 Litres

to 4C to 3C

DX 9.00 9.00 9.9 9.9

IB 13.50 13.50 15.0 15.0 Using Domestic Rural NightsaverUsing Domestic Rural Nightsaver

70% IB and 25% DX on Nightsaver70% IB and 25% DX on Nightsaver

to 4C to 3C

DX 8.458.45 9.319.31

IB 9.399.39 10.4310.43

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MILK COOLING COSTSMILK COOLING COSTS Nov 2007Nov 2007

Using Domestic Rural rateUsing Domestic Rural rateCost Cost €€ per 4500 Litresper 4500 Litres

to 4C to 3C

DX 9.00 9.00 9.9 9.9

IB 13.50 13.50 15.0 15.0 Using Domestic Rural NightsaverUsing Domestic Rural Nightsaver70% IB and 25% DX on Nightsaver70% IB and 25% DX on Nightsaver

to 4C to 3C

DX 8.458.45 9.319.31

IB 9.399.39 10.4310.43

Using Domestic Rural NightsaverUsing Domestic Rural Nightsaver100% IB and 50% DX on Nightsaver100% IB and 50% DX on Nightsaver

to 4C to 3C

DX 7.237.23 7.977.97

IB 7.207.20 8.008.00

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Annual Milk Cooling Efficiency

Milk Cooling Efficiency Milk Cooling Efficiency --mdcmdc 19971997 Nov 2007Nov 2007

30

40

50

60

70

80

90

100

110

Jan

FebMarc

hApril

MayJu

neJu

lyAug

Sept

OctNov

Dec

Month

Litr

es M

ilk p

er k

Wh

1800 L IB Old – 45L/kWh Avg

5200 L DX New Scroll – 87L/kWh Avg

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PRECOOLING MILK PRECOOLING MILK Nov 2007Nov 2007

Plate Cooler :

Jacketed Milk lines

Series of S.S. plates sandwiched together.Water and Milk flow in opposite directions through alternate spaces between plates.Each plate and gasket approx 3mm

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PLATE COOLERS PLATE COOLERS Nov 2007Nov 2007

Single Stage

Two Stage

Complex

epid tap water

Tepid tap water

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Instant Cooling - 2 Stage CW

0

1

2

3

4

5

6

7

0 15 30 45 60Time [mins]

Milk Temp out [C]CW inCW [2] outCW [1] out

Instant Cooling Instant Cooling Moorepark 1992Moorepark 1992 Nov 2007Nov 2007

MILK

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Savings using Plate CoolerSavings using Plate Cooler Nov 2007Nov 2007

Savings Possible if:• Plate Cooler is sized correctly• Water to Milk Ratio is 2:1

Water Inlet Milk Outlet % SavingTemp [C] Temp [C] in Cooling

1010 1515 6565

1515 1919 5050

2020 2323 4040

• Plate Cooler is sized correctly• Water to Milk Ratio is 1.5:1

Water Inlet Milk Outlet % SavingTemp [C] Temp [C] in Cooling

1010 17.517.5 5555

1515 20.520.5 4545

2020 2424 3737

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Savings using Plate CoolerSavings using Plate Cooler Nov 2007Nov 2007

Milk Cooled to 3C

• 50% cooling by water

• 4500 Litres cooled

• Domestic Rural electrical rate

[70% IB and 30% DX on Domestic Rural rate]

• Mains Water charge of €4 per 4500 Litres

• 2:1 Water to Milk ratio

Cost [€] per 4500 Litre Cooled

- No Shallow Deep Well MainsPC Subm. Surface

DX 9.9 5.40 5.40 6.5 13.00[9.31 5.00 5.00 6.1 12.7]

IB 15.0 7.88 7.88 9.0 15.5[10.43 5.5 5.5 6.6 13.2]

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Plate Cooler InstallationPlate Cooler Installation Nov 2007Nov 2007

• Mount as per instructions

• Connect as per instructionsWater and Milk flow in opposite directions

• Fit Filter on milk line before Plate Cooler

• Fit Filter on water line if needed

• Do not restrict outlets

• If water pressure is too high install pressure reducing valve

• Lag pipes if instant cooling

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SIZING A PLATE COOLERSIZING A PLATE COOLER Nov 2007Nov 2007

1. GET DAILY MILK YIELD

2. DIVIDE BY 2

3. ADD 33%

4. |SIZE COOLER FOR THIS FLOWRATE per HOUR

MILK COOLED NO. PLATESLitres /Hr Single Stage Two Stage

120 mm x 632 mm Plates

900

1125

1350

1800

2250

3000

17

21

23

29

35

45

33

39

45

57

67

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Evaporative Coolers Evaporative Coolers Nov 2007Nov 2007

MAY BE AN OPTION WHERE WATER IS NOT AVAILABLE FOR PLATE COOLER

CAPABLE OF COOLING MILK TO 20-22Cin WARM SUMMER WEATHER

PRECAUTIONS

• DRAIN WATER REGULARLY E2D

• INSTALL UNIT IN WELL VENTILATED AREAor OUTSIDE

• CLEAN DOWN UNIT REGULARLY

• MAKE PROVISION AGAINST FROST DAMAGE

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Milk Cooling OptionsMilk Cooling Options Nov 2007Nov 2007

1. Direct Expansion [DX]

2. Ice-Bank [IB]In tank ice-buildingExternal ice-building

3. DX or IB + Single stage Plate CoolerWater

4. DX or IB + Single stage Plate CoolerChilled water [Tank or Chiller unit]

5. DX or IB + Double stage Plate CoolerWater and Chilled water

Water can be Deep well, Shallow well, Mains or come from an Evaporative cooler.

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Milk Cooling Costs Milk Cooling Costs --SummarySummary Nov 2007Nov 2007

To Cool 4500 Litres Milk to 3C

DX IB

Std Electricity €9.9 €15.0

Night Rate €9.31 €10.4370% IB / 25% DXNight Rate €8.00 €8.00100% IB / 50% DX

Std Electricity €4.95 €7.5

Night Rate €5.18 €5.7570% IB / 25% DXNight Rate €4.50 €4.50100% IB / 50% DX

-Submersible Pump

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EFFECT OF PLATE COOLING EFFECT OF PLATE COOLING onon

BLEND TEMPERATURESBLEND TEMPERATURES NovNov 20072007

DX TANK DESIGN COOLING TIME: 2 Hours

MILKING TIME: 1 Hour

UC : Uncooled Milk PC: Precooled MILK

MILK BLEND TEMPS [C]TIME from START of MILKING [mins]

0

3518

4.04.0

4.04.0

4.04.0

60

2111

11.87.1

7.95.6

6.54.8

120

4.04.0

4.04.0

4.04.0

4.04.0

MILKING 1

MILKING 2

MILKING 4

MILKING 6

UCPC

UCPC

UCPC

UCPC

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Bulk Tank Purchase and InstallationBulk Tank Purchase and Installation Nov 2007Nov 2007

• GET WRITTEN QUOTATION

• ENSURE BULK TANK CONFORMS TO NEW EUROPEAN SPECIFICATION

EN 13732

• ENSURE ALL EQUIPMENT IS SIZED CORRECTLY

• ENSURE ALL EQUIPMENT ISINSTALLED CORRECTLY

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Sizing a Bulk Tank Sizing a Bulk Tank Nov 2007Nov 2007

Calculating capacity of Bulk TankCalculating capacity of Bulk TankHow many milkings do you need to store

at peak ?5 for E2D Collection

or

7 for E3D Collection

No. cows now and in 5 years time.

Yield per cow - 30 Litres/Day at peak[6.5 Gals/Day]

Example:Example:Herd Size: 50Bulk Tank Capacity for E2D:

50 x 30 x 2.5 = 3750 L [825 Gals]

Bulk Tank Capacity for E3D:50 x 30 x 3.5 = 5250L[1155 Gals]

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BULK TANK PURCHASE BULK TANK PURCHASE Nov 2007Nov 2007

Check size of Dairy.•Have at least 600mm clear space around tank for cleaning.

Extra space may of course be required for other equipment eg Wash trough is major item – you need 900mm space to work at this

This may decide what type or make of tank you buy.This may decide what type or make of tank you buy.ieie Differences in dimensions between manufacturersDifferences in dimensions between manufacturers

DX may fit in where IB would not.DX may fit in where IB would not.••Is there sufficient headroom above tank for sampling, Is there sufficient headroom above tank for sampling,

inspection, service. inspection, service. Have 2 M above platformHave 2 M above platform•Does Dairy need extension, modification etc.• Is Electrical, Plumbing, Milking M/C etc OK.

Get detailed written quotation stating:• Make, Type and Model of tank• Rated Capacity• Make, Model and HP of Condensing Unit• Details of Automatic Washer• Details of new Pre-Cooling system or proposed

modifications to existing system.• Rough sketch of where Bulk Tank and any ancillary

equipment fits into dairy.• Clarification of who does what re. any building work,

plumbing, electrical or modifications to milking m/c.

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Bulk Tank Installation Bulk Tank Installation Nov 2007Nov 2007

Ensure all preparatory work is completed• Building Work• Electrical Work• Plumbing Work• Milking M/c modification

• Position of Tank in Dairy • Position of Icebuilder• Siting of Condensing Unit[s]

Remember they need to be serviced so easy access is important.

• Position of Control Panel• Adequate Space around tank [600mm]

• Adequate headroom [2 M above platform]

• Pipework Refrigeration Plumbing [pipe insulation –HW and CW

• Electrical Work• Hot Water supply to washer• Operation of Tank

• Care of Tank

Instuctions / Instruction BookFunction of all switchesCoolingWashing and DetergentsEmptyingFault FindingInspection of Ice bank

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CONDENSING UNIT LOCATIONCONDENSING UNIT LOCATION Nov 2007Nov 2007

CLEAN UNRESTRICTED CLEAN UNRESTRICTED AIR SUPPLY REQUIREDAIR SUPPLY REQUIRED

Most Condensing Units are now positioned outside

Ensure protection cowl is adequate

Protects unit from rain, birds etc Ensures adequate ventilationHas crankcase heater fitted

Keep away from feed bins, hay bales etc

Keep away from Milking M/C exhaust

Extractor fan may be required if positionedin plantroom with Milking M/C etc

Ensure it can be accessed easily for service

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Bulk Tank Servicing Bulk Tank Servicing Nov 2007Nov 2007

Planned Preventative Maintenance is EssentialAnnual Routine Visit:• Check List• Written Report for Farmer

If a fault is found :• It should be Rectified

or

• A note put on Report Form detailing action.

All Bulk Tanks should have clear Operating Instructions posted on dairy wall [weatherproof]• Switch Functions• Cooling• Washing inc. recommended Detergents• Emptying• Fault Finding• Care of Tank and ancillary equipment

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SERVICING YOUR BULK TANKSERVICING YOUR BULK TANK Nov 2007Nov 2007

Check condition of Condensing Unit regularly Clean if dirty. Straighten fins if dented or pressed

against each otherCheck occasionally that condenser fan[s] is[are] runningIf IB - check ice formationKeep regular check on cooling times.

Slow cooling may be first sign of a problem. Keep regular check on milk temperature ie before each milking and at end of milking,

Check agitator and intermittent agitationCheck that tank is not causing excessive buttering/foamingCheck that there is no ice formation in milk in DX tanks.Check operation of automatic washer regularly.Is hot water temperature correct ?-should be approx 70CCheck condition of inside of tank after wash Use bright light.

Report any malfunction to serviceman as soon as possibleA stitch in time .......

Things the Farmer should do

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BULK TANK PURCHASE BULK TANK PURCHASE Nov 2007Nov 2007

Buying A 2nd Hand Tank:

A 2nd hand tank may be an option. Tanks have a life span of at least 20 years and many tanks are still in good condition after over 30 years operation.IB Tanks repolished and fitted with new copper

coil evaporators are like new.However some DX Tanks over 20 years old may not be able to withstand pressures developed by modern Refrigerants.

If Buying a 2nd Hand Tank:

• Buy from a reputable dealer

• Check age of tank.

• If you buy direct from farmer get reputable refrigeration engineer/serviceman to check it out.

• If tank is over 7/8 years old install new condensingunit.

• Always get reputable refrigeration engineer/servicemanto move tank and ancillary equipment.

46

TANK CAPACITY CONDENSING UNIT5 Milking 7 Milking HP

Ltrs [Gls] Ltrs [Gls]

1820 [400] 2550 [560] 2.5

2140 [470] 3000 [660] 3.0

2640 [580] 3700 [815] 4.0

3860 [850] 5400 [1200] 5.0/5.5

TYPICAL CONDENSING UNIT SIZESTYPICAL CONDENSING UNIT SIZESforfor

DIRECT EXPANSION TANKS DIRECT EXPANSION TANKS Nov 2007Nov 2007

IB Tanks will have smaller condensing unitsIB Tanks will have smaller condensing units

47

Food Processing MachineryBulk Milk Coolers on the Farm

Requirements for construction, performance, suitability for use, safety and hygiene

EN 13732

• Scope, References, Definitions• Hazards - Related to intended conditions of use

MechanicalElectricalRefrigerantMaterials usedHygiene PrinciplesErgonomic PrinciplesUnexpected start-up

• RequirementsMechanicalAgitatorsElectrical and ControlsCooling, Storage and Agitation performancePrevention of milk contaminatioOutlets, InletsRequirements for Ice bank and Vacuum Tanks

• Verification and Tests• Information on use, Instructions

etc

Instant inInstant in--line cooling and line cooling and PrecoolingPrecooling not includednot included

European Standards European Standards Nov 2007Nov 2007

48



EN 13732

Cooling Performance is based on:

• Number of Milkings ie ED, E2D, E3D

• Ambient TemperatureClassification Performance Temp Safe Operating

Temp [SOT]A 38C 43CB 32C 38CC 25C 32C

• Cooling TimeClass Max Cooling Time to cool any milking

from 35C to 4C0 2.0hr1 2.5 hr11 3.0hr111 3.5hr


49

Washing Systems Washing Systems Nov 2007Nov 2007

Packo Eco –Wash Cycle on 4500L Tank:[Flush out system + Dilution] [Shorter Cycle and less water]

1. 2 Pump flushes with cold water 15L x 22. Hot circulation wash 3.5 mins 50L3. Main Cycle – Hot circulation wash

with Chemical of 9.5 min 50L4. Final Cycles – 3 Cold water flushes 15Lx3

Total Cleaning Cycle = 30 mins Water used 175LOn old Packo : Cycle = 50 min Water used 250L

7200L Tank: Eco 1.1kWh Pump, 219 L water, 30 mins

Std 1.1kWh Pump, 360L wate, 50 mins

8000L Tank Eco 1.5kWh pump, 2 agitators, 325L water32mins

Std 1.5kWh pump, 2 agitators, 500L water 60-90 mins

17500L Tank Eco 1.5kWh pump, 23agitators, 385L water32mins

Std 1.5kWh pump, 3 agitators, 650L water 60-90 mins

Old Packo wash cycle: [Dilution system]1. Pre-rinse 50L cold2. Pre rinse 50L warm3. Main wash 50L warm + Chemical4. Post-rinse 50L x 2 cold

Total: 250 L

50

Bulk Tank Companies – Nov 2007

Dari-KoolCharleville Refrigeration,Station Rd,Charleville,Co Cork David O’Connor, Pat O’Connor 063 89101 087 2595673

Delaval,Unit 6,Shamrock Business Park,Graiguecullen,Carlow Brian Harte 059 9146859

Liscarroll TanksAssociated Steel Engineering,LiscarrollCo Cork Tim Brosnan 022 48200

MuellerKingston Refrigeration and Electrical Services Main DealerEdencurra,Dunmanway,Co Cork Sam Kingston 023 45420

Denis O’Brien 086 2558952John O’Neill 086 8360414

Intercool Engineering Ltd, - Dealer North Leinster and UlsterKells,Co Meath Gene Orminson 086 2577071

Packo Ireland,Ballymaquirke,Kanturk,Co Cork Willie Walsh / Andy Buckley 029 56097

KilkennyStainless Steel Fabrications Ltd,Hebron Rd,Kilkenny Paddy Smee, Ann Smee 056 7722913

John O’KeeffeTeagasc,Moorepark

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COST of ELECRICITYCOST of ELECRICITY

Domestic RuralDomestic Rural 15.00 c/ kWh15.00 c/ kWh [Unit] [Unit]

Domestic Rural Domestic Rural Day Day 16.1 c / kWh [Unit] 16.1 c / kWh [Unit] NightsaverNightsaver NightsaverNightsaver 8.0 c / kWh [Unit]8.0 c / kWh [Unit]

Volume Cost [€]Litres Std Electric Nightsaver

Rural Domestic Electric Oil

100 1.16 0.61 0.64

200 2.32 1.22 1.28

300 3.48 1.83 1.92

Hot water Temperature: 75C

Thermostat setting: 77CHeater size: 200 Litre

Draw off Temperature profile from ElectricPressure Water Heaters

Water Heating Water Heating Nov 2007Nov 2007

COST of 35 sec OILCOST of 35 sec OIL

64c per Litre 64c per Litre

Draw off Blend Temp [C] Cumulative Volume Blend Temp [C]1st 50 Litres 77C 77C2nd 50 Litre 76C 76C3rd 50 Litres 66C 73C4th 50 Litres 40C 65C

52

Water Heating Water Heating Nov 2007Nov 2007

Cost of Hot Water for 50 cow herd6 Unit Milking Machine

Routine Electricity Cost per year [€]

Rural Domestic NightsaveRate Rate

Once/Day M/C hot wash 180 88

Bulk Tank Hot Wash AD 97 48

Udder Washing 162 80

Total 439 216

Milk Cooling @ €5 to €16 per cow = €250 to €800[Yield 4500 L/Cow]

53

MILK COOLING DATAMILK COOLING DATA Nov 2007Nov 2007

Copeland Scroll Condensing Units - R404A

ModelModel HP Output Kcal/hrHP Output Kcal/hr Bulk Tank Cap [Litres]Bulk Tank Cap [Litres]25C 25C AmbAmb. . 7 Milkings7 Milkings

0C 0C EvapEvap --10C 10C EvapEvap

MC-H8-ZB19KE 2.5 5745 4166 2550 [560Gal]

MC-H8-ZB21KE 3.0 6666 4912 3000 [660Gal]

MC-H9-ZB26KE 3.5 7760 5736 3500 [770Gal]MC-H8-ZB26KE 3.5 7456 5526 3370 [740Gal]replaces MC-H9-ZB26KE

MC-M9-ZB26KE 4.0 8307 6026 3700 [815Gal]Special for RDL Irl

MC-M8-ZB42KE 5.0 11579 8728 5000 [1100Gal]For IB Tanks

MC-R7-ZB42KE 5.5 12,807 9430 5400 [1200Gal]

MC-M8-ZB45KE3Ph 5.5 11930 8991 5380 [1180Gal]

MC-R7-ZB56KE3Ph 7.5 14649 10965 6610 [1450Gal]

MC-V9-ZB75KE3Ph 10 21755 16316 9820 [2160Gal]

Mueller HiPerform 5.0 13000 5870 [1290 Gal]Copeland ZB42KCE Dutch Data/American Data

Maneurop 4.0 7080? 3190 [700 Gal]

54

MILK COOLING DATAMILK COOLING DATA Nov 2007Nov 2007

York/Bristol Condensing Units Inertia or Scroll - R404A

ModelModel HPHP Output Kcal/hrOutput Kcal/hr Bulk Tank Cap ]Litres]Bulk Tank Cap ]Litres]25C 25C AmbAmb. 0C . 0C EvapEvap 7 Milkings7 Milkings

ACU7-24QA Inertia 2.0 4600 2000 [450Gal]



ACU7-373A Scroll 2.5 7240 3270 [720Gal]

ACU7-453A Scroll 3.0 8760 3950 [870Gal]

ACU7-603A Scroll 3.5 11,543 5200 [1100Gal]

55

BULK TANK DIMENSIONS BULK TANK DIMENSIONS Nov 2007Nov 2007

Capacity Make Type Length Width HeightLitres DX/IB M M M

3000 DeLaval DX 2.44 1.80 1.903000 Dari-Kool DX 2.88 1.57 1.872950 Kilkenny DX 3.02 1.57 1.772300 Liscarroll DX[Enc] 2.39 1.57 1.802500 Liscarroll DX[open] 2.87 1.50 1.342300 Liscarroll IB[Enc] 2.32 1.57 1.802500 Liscarroll IB[Open] 2.81 1.50 1.342530 Mueller DX [O 600] 2.78 1.53 1.562745 Mueller DX [P 2600] 2.89 1.33 1.792600 Packo DX[REM] 2.69 1.66 1.852800 Packo IB[RMIB] 2.69 1.80 2.002300 Packo IB [Open] 3.13 1.46 1.43

4500 DeLaval DX 3.34 1.80 1.904500 Dari-Kool DX 3.56 1.84 1.854540 Kilkenny DX 2.92 1.98 2.144500 Liscarroll DX 2.89 2.00 1.984500 Liscarroll IB 2.82 2.00 1.984580 Mueller DX[0 1125] 3.40 1.79 1.814340 Mueller DX[P 4100] 3.67 1.44 1.885080 Mueller DXPC 5000] 2.98 1.74 1.915000 Packo DX[REM] 3.99 1.80 1.845000 Packo IB[RMIB] 4.05 1.80 2.00

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9700 DeLaval DX 4.56 2.15 2.2510000 Dari-Kool DX 3.34 2.44 2.7210000 Kilkenny DX 4.01 2.39 2.5410000 Liscarroll DX 3.49 2.50 2.4810000 Liscarroll IB 3.42 2.50 2.4810020 Mueller DX[O 2500] 4.20 2.27 2.1810000 Mueller DX[P 10000] 4.20 1.98 2.4310000 Packo DX[REM] 4.80 2.23 2.2110000 Packo DX[LEM] 4.77 2.03 2.4410000 Packo DX[LEM Short]4.41 2.13 2.5510000 Packo DX[LEM A] 4.14 2.20 2.619650 Packo IB[RMIB] 4.73 2.26 2.53

14000 DeLaval DX 5.22 2.27 2.6313000 Dari-Kool DX 4.24 2.44 2.7515000 Liscarroll DX 4.99 2.50 2.4815000 Liscarroll IB 4.92 2.50 2.4815670 Mueller DX[O 4000] 5.54 2.45 2.2915460 Mueller DX[P 15000] 4.63 2.24 2.7015000 Packo DX[REM] 6.76 2.23 2.2115500 Packo DX[LEM] 6.35 2.13 2.5514000 Packo DX[LEMShort] 4.24 2.50 2.9215000 Packo IB[REMDIB] 6.46 2.23 2.2115500 Packo IB[LEMDIBShort]6.02 2.13 2.55


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20000 DeLaval DX 5.55 2.52 3.1220000 Dari-Kool DX 6.28 2.44 2.7920000 Liscarroll DX 6.50 2.50 2.4820000 Liscarroll IB 6.49 2.50 2.4820555 Mueller DX[0 5000] 5.39 2.80 2.6021785 Mueller DX[P 2000] 4.96 2.62 3.1421000 Packo DX[LEM] 8.40 2.13 2.5521000 Packo DX[LEMShort] 5.89 2.50 2.9221000 Packo IB[LEMDIB 8.07 2.13 2.55

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Milk Silos

Capacity Make Width HeightLitres M M

12000 Packo 2.61 3.6815500 Packo 2.61 4.4218000 Packo 3.0 3.9521000 Packo 3.0 4.5125000 Packo 3.0 5.133,000 Packo 3.0 5.76

11,300 Liscarroll 2.55 3.6015,035 Liscarroll 2.55 4.2020,357 Liscarroll 2.97 4.2025,206 Liscarroll 2.97 4.9530,056 Liscarroll 2.97 5.7041,063 Liscarroll 3.50 5.70

59


Approx Icebuilder sizes:

Make Conden. Cooling Length Width HeightUnit HP Cap. kCal M M M[ 12 Hr

Icebuilding]

Kilkenny 3.0/3.5 51000 1.91 1.22 1.45Liscarroll 3.0/3.5 54000 1.56 1.36 1.31Dari-Kool 3.0/3.5 60200 2.15 0.98 1.65Packo 3.0/3.5 60000 1.78 1.00 1.76

Kilkenny 4.0/5.0 76800 2.24 1.22 1.70Liscarroll 4.0/5.0 71500 1.81 1.71 1.31Dari-Kool 4.0/5.0 86000 2.97 0.98 1.72Packo 4.0/5.0 80000 2.03 1.00 1.76

Kilkenny 2x3.0 120000 2.74 1.47 1.70Liscarroll 2x3.0 122000 1.81 2.12 1.47Dari-Kool 2x3.0 129000 2.97 1.42 1.75Packo 2x3.0 120000 1.85 1.95 1.76

Kilkenny 2x5.0 164000 3.10 1.88 1.73Liscarroll 2x5.0 186000 1.96 3.12 1.47Dari-Kool 2x5.0 172000 2.97 1.97 1.72Packo 2x5.0 160000 2.21 1.95 1.76

Kilkenny 2x7.5 240000 3.25 2.08 1.98Kilkenny 2x7.5 389000 3.40 2.34 2.49Dari-Kool 2x7.5 258000 2.97 2.84 1.75Packo 2x7.5 320000 2.30 4.00 1.62

Add 1.20M to Length for end mounted condensing unitsAdd 0.56M to Height for top mounted condensing units

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Ice Builder Cooling Capacities Ice Builder Cooling Capacities Nov 2007Nov 2007

Approx Icebuilder sizes:Make Conden. Cooling Tank Capacity [Litres]

Unit HP Cap. kCal 5 Milking 7 Milking [ 12 Hr

Icebuilding]

Kilkenny 3.0/3.5 51000Liscarroll 3.0/3.5 54000 4400 6200Dari-Kool 3.0/3.5 60200Packo 3.0/3.5 60000

Kilkenny 4.0/5.0 76800Liscarroll 4.0/5.0 71500 6100 8600Dari-Kool 4.0/5.0 86000Packo 4.0/5.0 80000

Kilkenny 2x3.0 120000Liscarroll 2x3.0 122000 9700 13500Dari-Kool 2x3.0 129000Packo 2x3.0 120000

Kilkenny 2x5.0 164000Liscarroll 2x5.0 186000 13700 19200Dari-Kool 2x5.0 172000Packo 2x5.0 160000

Kilkenny 2x7.5 240000 20000 27000Kilkenny 2x7.5 389000 31300 44000Dari-Kool 2x7.5 258000 20000 27000Packo 2x7.5 320000 25800 36000

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• EU Council Resolution on new approachto Technical Harmonization and

Standards.

• EU Directives limited to Essential Safetyor other performance requirements in general public interest.

• Technical Details left to CEN, CENELECand ETSI.

European Standards [EN]:

• Tools to help manufacturers and users comply with Directives. [Guidance on meeting requirements]

• Standards are not mandatory

• Standards give details on recommended solutionsthat follow Directives ie Mechanical toolkit

• Other Countries adapt them for their own useie USA , Japan

• A B and C Standards

1985

62

European Standards [EN] Process

Working Group of Experts set up

Group Draft a Standard

Vote on Draft Standard by European Countries71% votes in favour required


63



Working Group CEN TC 153/WG8 set upTo write up PrEN13732

First Meeting in Paris in Oct 1990

Working Parties set up by Group

Group CEN TC 153/WG8 write up PrEN13732

Ad-HocGroup 1GENERAL

Ad-HocGroup 2CLEANING

Ad-HocGroup 3SAFETY

Vote by European Countries approves PrEN13732


64

Cost of Bulk Milk Tanks - Nov 2007

Personal communication – Willie Walsh, PackoIB €17.50 per Gal+ VAT €4 per Litre €4.54 / L incl 13.5% VATDX €15 per Gal + VAT €3.3 per Litre €3.7 / L incl a3.5% VAT

Prices decrease as capacity increases

Farmer Journal Survey

IB €5.1/L £23/Gal

ICEBUILDERS <100,000 kCals €182 / 1000 kCal100,000 – 150,000 €179 / 1000 kCal>150,000 €150 / 1000 kCal

DX <5000L €4.5/L £20/Gal5000 – 10000L €3.30L £15.0/Gal>10000L €3.0/L £14.0/Gal

WATER Heaters €5 / Litre

EXAMPLE of BULK TANK COST:

4500 L [1000 Gal] for E2D Collection6400 L [1400 Gal] for E3D Collection

Type E2D E3D

DX €20,000 €22,500

IB €23,000 €27,500

ICEBUILDER €18,000

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Economics of ‘Domestic Rural Nightsaver’ Electricity - Nov 2007

Cost: Once off connection fee [From Jan 2007] : €255Extra standing charge: €6.20 / 2 months €37.23 / yearCost of Units Day: 16.1 c/kWh

Night: 8.0 c/kWh

Cost of Units on ‘Domestic Rural’: 15.0 c/kWh

50 Cow Dairy Farm

Usage at 250kWh/cow/ year: 12500 UnitsDomestic: 6000 UnitsTotal 18500 Units

Cost:

Domestic Rural Nightsaver70% on Day / 30% on Night €2529

On Domestic Rural €2775Saving €246





100 Cow Dairy Farm

Usage at 250kWh/cow/ year: 25000 UnitsDomestic: 6000 UnitsTotal 3100 Units

Cost:







A farmer with 50 cows , using 25% energy on Night units could taA farmer with 50 cows , using 25% energy on Night units could take up toke up to3 years to break even 3 years to break even ––after paying initial installation fee.after paying initial installation fee.

If already installed you need to use at least 15% of energy If already installed you need to use at least 15% of energy on Night units.on Night units.

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Milk Cooling EfficiencyJohn O’Keeffe – Teagasc, Moorepark [January 2007]

In the early 90’s when we finished our test programme on milk cooling equipment at Moorepark the accepted overall cooling efficiency figures for milk cooling and holding for two days under Irish conditions were:36 to 45 Litres/kWh for Chilled water tanks cooling and holding at 4C55 to 68 Litres/kWh for Direct Expansion tanks cooling and holding at 4C.Since that time there have been many major changes to the tanks themselves, their control systems, the refrigeration compressors used and the refrigerants. All these changes have improved the coolingefficiency. However there are now no National Institutes that I know of testing equipment in the test roomor monitoring it over an extended period at farm level so accurate data on efficiency is hard to come by.The overall cooling efficiency figures we have been using for the past two years are: 50 Litres/kWh for Chilled water tanks cooling and holding at 4C.75 Litres/kWh for Direct Expansion tanks cooling and holding at 4C.When you go to every third day collection you will need to cool to as close to 3C as possible and holdat this temperature so efficiencies will once again drop slightly ie45 Litres/kWh for Chilled water tanks68 Litres for Direct Expansion tanks.This slight loss in cooling efficiency will be offset somewhat by a lesser no. of tank washes.

Many older installations are of course not working efficiently for many reasons:Even when serviced regularly:• Compressors drop in efficiency after about 7 years• Siting of compressors not great in many older installations • Control of temperature is not as accurate as modern tanks• Insulation not as good as modern tanks and may have deteriorated with age.

Some of these older installation are not serviced on a regular basis and the effficency drop could be asmuch as 50% in some of those installations where condensers are dirty or damaged, refrigeration charge

is low, valves gone out of adjustment , thermostats faulty etc.

Comparing a new tank to an existing installation:Replacing a 20 year old vertical cylindrical shaped DX tank with a modern enclosed DX tank could improve cooling efficiency from 45 Litres/kWh to 68 Litres/kWh.This of course, apart from an inefficient Chilled water tank on Day Rate electricity, is the worst possible scenario. Many old tanks up to 10 years old eg enclosed horizontal cylindrical are working efficiently and will comtinue to do so for many years. They may need a Compressor change and maybe a Refrigerant change at some future date.

Chilled Water v Direct Expansion Both will cool and hold the milk equally well.When using Night Rate Electricity – and practically all dairy farmers are now using it - the cooling costs for Chilled water and Direct Expansion are usually very similar assuming about 25% Direct Expansion and70% Chilled water cooling is done on the cheaper Night Rate.

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Cost Cooling 454,600 Litres [100,000 Gallons] Milk to 4C:[On Night Rate electricity – 25% on Night rate]] New DX Tank:cooling 75 Litres/kWh Cost : €86120 year DX old vertical Direct Expansion cooling 45 Litres/kWh Cost: €1436[July 2007 ESB Costings ]

Flooded Evaporator Systems:We did some test work on the Mueller Hiperform system in 1993 and found it to be slightly more efficientthan conventional DX systems available at the time. However the test work was not very comprehensiveand there have been so many changes with compressors, refrigerants, controls etc since that time that I amnot in a position to say how much more efficient it might be now

Cork Co Council Water Charges – July 2007

Same charge all over Co Cork at this stage.

Connection charge: €600Domestic allowance of €200 ie 224 m3 [224,000 Litres] [49.000 gals]

140 Gals/DayCost per m3 [1000 Litres]: 89c ie €4.05 per 4500 Lires [1000 Gals]

There is also an OUT charge if Council take waste:IN / OUT : €1.95 per M3

There is also an IN/OUT Domestic allowance of €439 NOTE IN above is €200

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