After a successful collaboration at its Kariega further processing facility, leading South African poultry producer Sovereign has once again partnered with Energy Partners (EP) to implement Cooling-as-a-Service (CaaS) at its Hartbeespoort (HBP) facility.

EP, South Africa’s pioneer of CaaS, took on the challenge of upgrading Sovereign’s outdated refrigeration infrastructure by decommissioning two separate, outdated plants and constructing a new, centralised system. This new facility meets Sovereign’s cooling requirements while adhering to strict noise regulations, all with minimal disruption to production.

“EP managed to reduce disruptions to the absolute minimum, even though Sovereign operates six days a week. The transition from the old plant to the new system was seamless,” explains Sovereign engineering manager Stephan Oosthuizen.

The new refrigeration system has not only improved operational efficiency but also created a more sustainable and scalable cooling solution for Sovereign’s growing production demands.

A R92m Cooling-as-a-Service Partnership

EP’s CaaS model takes the burden off Sovereign, with EP investing 100% of the capital investment of R92-million to design, construct and operate the refrigeration plant over a 15-year period. This shift in responsibility removes operational risks tied to downtime, efficiency and ongoing maintenance, freeing Sovereign to focus on expanding production.

“We’re incredibly proud of the work we’ve done for Sovereign,” says EP Asset Management GM Coenrad Ehlers. “By replacing outdated infrastructure with a state-of-the-art ammonia refrigeration system, we’ve enabled Sovereign to reinvest their capital and human resources into their core business.”

Advanced Technology for Sustainability and Efficiency

The heart of the new system is a highly efficient, three-stage ammonia refrigeration process that delivers a combined refrigeration capacity of 5.47 MWR. The design maximises cooling efficiency and ensures the system is scalable to meet future growth in cooling demand.

To boost energy efficiency, EP integrated several key features, including a master control system that optimises the entire refrigeration process. Compressors and condensers equipped with variable speed drives allow for superior energy management, while a heat reclaim mechanism reduces boiler fuel use by capturing and repurposing waste heat to preheat water.

This technology has already resulted in a 20% energy saving, a critical benefit given the facility’s electricity constraints. EP’s implementation of digital twin technology plays a significant role in achieving these savings by allowing precise monitoring and optimisation of the system’s performance.

Data-driven Monitoring for Optimised Performance

A major feature of the CaaS model is EP’s ability to provide remote monitoring and 24/7 oversight of the plant’s operations. This approach allows potential issues to be identified before they escalate, ensuring uninterrupted cooling performance.

“You can’t manage what you can’t measure,” Oosthuizen emphasises. “EP’s monitoring system gives us real-time insights into how the plant is performing and helps us quickly spot areas for improvement.”

Noise Control and Compliance

In addition to cooling efficiency, noise control was a major consideration for the new plant. To meet noise level regulations, the plant room was constructed with double brick walls, rock wool ceilings and specialised acoustic doors.

Other noise-reduction strategies include strategically placed condensers and noise attenuators within the ventilation system, ensuring the plant operates quietly without compromising performance.

This latest project at Sovereign’s HBP facility marks the second time the company has turned to EP’s CaaS model, having already experienced its value at their Kariega site. The ongoing partnership is a testament to EP’s ability to deliver innovative, efficient and sustainable energy solutions.

As Ehlers concludes, “It’s very rewarding that Sovereign continues to trust us with their critical infrastructure needs. Our shared commitment to innovative and sustainable solutions is what makes this partnership so successful, and we look forward to building on this foundation in the future.”

As industries across South Africa continue to seek out more efficient and sustainable energy solutions, EP’s CaaS model is proving to be a game-changer for other clients like Dr Oetker, Clover SA and Letaba Packers.

By shifting operational risks away from businesses like Sovereign and allowing them to reinvest capital and focus on their core operations, EP is paving the way for a more sustainable and efficient future in industrial refrigeration.

Could CaaS be the game-changer your plant needs? Reach out to Samuel Jacobs to explore how Energy Partners can optimise your plant’s performance.

(031) 702 3111, cell: 074 726 4710, or via email at samuelj@energypartners.co.za