- Industry: Dairy Manufacturing: Enriched Powdered Milk and Bulk Butter
- Application: Chilled System and Closed Circuit Cooler Heat Exchange Loop
- Problem: Microbiological fouling in cooling and heat exchanger systems causing increase in energy use and production losses
- Solution: Get Clean, Keep Clean approach utilising patented bioeXile technology
- Results: 27% reduction in energy consumption, i.e. €84k energy savings and 132 tons CO₂ emissions saved in less than 9 months + Elimination of the temperature induced product quality issues and losses.
Prior State (Condition)
A large European dairy manufacturer produces enriched powdered milk and bulk butter exported to over 50 countries globally.
The cooling system was not meeting design efficiency, resulting in increasing energy consumption, costs and limited production. Most importantly, the insufficient cooling was having a negative impact on how much product could be processed during a season.
Initial survey pointed to biofilm formation, restricting flow and reducing heat exchange efficiency.
Proposed State and Justification (Recommendations)
Our team evaluated the facility and found that the root of the problems came down to biofouling in the service water systems providing the process cooling. Biofilm and biofouling is common in these applications, restricting flow and also acting as a thermal insulator.
To address this challenging issue, we recommended the facility engage in the ‘Get Clean, Keep Clean’ approach—our 360° approach to water treatment—targeting the removal of biofilm and restoration of system design efficiency.
Corrective Actions
Our solution was implemented in two concise phases:
Get Clean:
Our Water Treatment Specialist deployed Chem-Aqua’s patented bioeXile-L—a powerful biofilm penetrant—alongside an effective biocide. The system was circulated for 24 hours through pipework, cooling jackets, and heat exchangers before a thorough flush. Microbiological sampling showed a significant increase in Pseudomonas bacteria, confirming successful mobilisation and removal of biofilm.
Keep Clean:
Following the deep clean, we dosed the system with tailored corrosion and scale inhibitors and biocides, coupled with regular monitoring. This phase was designed to prevent reformation of biofilm and restore overall system design efficiency.
This 360° approach not only mitigated biofouling risks but also optimised long-term operational performance.
Results and Impact
Substantial energy savings throughout the peak production season from March to October (weeks 9-38):
- Cooling efficiency restored
- 27% energy savings / €84 K during the high production season and hottest summer on record
- Sustainability and carbon footprint improvements: 132 metric tons CO₂ emission saved
Customer testimonial
“ The clean carried out [by Chem-Aqua] greatly reduced the energy usage of the refrigeration system and reduced the cooling load on the same system. In turn we had less down graded product as the plant was able to reach the desired temperature. I would recommend a [bioeXile-L] clean every year.” – Site Engineering Manager
