Cooling Solutions for Dairy Plants: BUCO Falling Film Chillers & Ice Storage

Advanced dairy cooling safeguards product quality while cutting energy use, improving hygiene, and enhancing operational safety. For dairy processors, BUCO falling film chillers and ice storage (ice maker or ice bank systems deliver reliable ice water at near-freezing temperatures with low maintenance and high uptime.

Why Upgrade: Benefits that Matter to Plant Managers

Energy Efficiency (lower kWh per gallon cooled)

Modern dairy cooling uses ice water (≈32,5–35.6°F / 0.3°C–0.5°C) to achieve rapid heat transfer, shorten cooling times, and reduce compressor run hours – especially when paired with night-rate power and peak-shaving strategies. Optimized setpoints and load shifting translate into measurable energy savings and lower demand charges.

Flexibility (match cooling to production reality)

Ice storage decouples refrigeration capacity from moment-to-moment demand. Plants can build ice during off-peak hours and melt it during surge periods – balancing pasteurization, fermentation, filling, and CIP schedules without oversizing compressors. Falling film direct-cooling modules scale in parallel for line expansions.

Hygiene & Food Safety (clean design, cold water)

Direct ice-water cooling minimizes contact surfaces and keeps process water cold enough to inhibit microbial growth. Stainless steel cooling technology with accessible surfaces simplifies cleaning and inspection, supporting HACCP programs and regulatory compliance.

Cost Savings (CapEx & OpEx)

Reduced refrigerant charge (ammonia), smaller peak capacity, and low-maintenance cooling cut life-cycle costs. Retrofitting (rather than replacing) existing tanks and utilities further shortens payback and preserves floor space.

How the Technologies Work (Technical Principles)

Falling Film Chiller (Direct Ice-Water Cooling)

A controlled volume of water “falls” over vertical heat-exchange plates. Ammonia refrigerant evaporates on the opposite side, extracting heat and producing ice water close to 32.5°F-35.6°F (0.3°C–2°C). The falling film maintains high heat-transfer coefficients and tolerates incidental icing without mechanical damage, supporting low-risk, low-maintenance operation.

Ice Storage / Ice Bank Tank (Thermal Buffer)

An ice bank stores cooling energy as a latent “battery.” During off-peak hours, the ammonia system builds ice on heat exchangers. During production peaks, this ice melts to supply large volumes of 32.5°F-35.6°F (0.3°C–2°C) ice water to plate heat exchangers, process water loops, and jacketed tanks – without spiking compressor load.

System Operation for US Dairy Applications

Typical Process Flow

1. Ice-water generation via BUCO falling film chiller and/or Ice maker/ice bank.
2. Distribution to plate heat exchangers (raw milk reception, pasteurizer regenerator trim), product tanks, and packaging lines.
3. Return loop with temperature-controlled mixing to maintain 32.5°F–35°F (0.3°C–2°C) delivery.
4. Automation & controls coordinate night ice-building and day melting, prioritize critical loads, and log KPIs (kW/ton, °F approach, gpm, ΔT).

Refrigerant & Materials

• Ammonia refrigerant (R717) for thermodynamic efficiency and low GWP.
• Stainless steel cooling technology ( wetted parts and frames ) for hygiene, durability, and corrosion resistance.

Maintenance Practices

• Open, accessible plate areas for visual inspection and easy cleaning.
• Predictive maintenance via temperature approach trends and pump/VFD analytics.
• Seasonal setpoint optimization to reduce frosting risk and fan energy.

Upgrading Paths & Retrofitting Options

Add a Falling Film Chiller to Existing Loops

Install a BUCO falling film module upstream of existing plate heat exchangers to reach lower approach temperatures and stabilize outlet ice-water temperature – often without replacing distribution piping.

Convert a Chilled-Water Tank to an Ice Bank/Ice Maker

Where production peaks overwhelm chiller capacity, retrofit the tank with an Ice bank/Ice maker package to create thermal storage and shift load to off-peak rates. Controls integrate with current PLC/SCADA for automated day/night modes.

Hybrid: Direct Cooling + Ice Storage

Combine falling film (for base load and precision temperature control) with an Ice maker/Ice bank (for peak trimming and redundancy). This hybrid approach delivers resilience for seasonal volume spikes or added product lines.

Economic Impact & Decision Framework

Where Savings Accrue

• Energy savings: Higher evaporating temps during ice building, reduced compressor cycling, VFD pump/fan turndown, and off-peak power.
• Demand reduction: Peak-shaving with ice storage lowers demand charges.
• Lower TCO: Smaller refrigerant charge (ammonia), stainless construction, and low-maintenance cooling extend asset life and reduce service cost.

Quick Screening Metrics

• Cooling duty (MBH / kW) across peak hour blocks.
• Ice Maker/Ice Bank size (ton-hours) to cover defined surge windows.
• Approach temperature (ΔT to product/medium) and target outlet (32°F–35°F).
• Payback period from energy, demand, and deferred CapEx.

Technical Overview (Easy-Reference List)

• Ice water delivery: 32.5°F-35.6°F (0.3°C-2°C); falling film down to ~32.9°F (0.5°C) for rapid heat transfer.
• Technologies: BUCO falling film chiller (direct cooling) and BUCO ice storage / ice bank tank (thermal accumulation).
• Refrigerant: Ammonia refrigerant (R717) for high efficiency and low environmental impact.
• Construction: Stainless steel cooling technology with accessible surfaces for fast cleaning and inspection.
• Controls: PLC/SCADA integration, automated day/night modes, peak-shaving logic, KPI dashboards (gpm, ΔT, kW/ton).
• Energy strategy: Night electricity rate cooling, demand reduction, VFD pump/fan control, approach-temperature optimization.
• Integration: Plate heat exchangers, process water loops, jacketed tanks, and CIP support.
• Reliability: Ice-tolerant falling film geometry; low-maintenance cooling hardware; modular redundancy.
• Retrofits: Add falling film to existing chilled-water loops; convert tanks to ice banks; hybrid configurations.
• Compliance & safety: Hygienic design supports food safety programs; reduced refrigerant inventory.

Conclusion: Customizable Cooling, Proven Business Value

BUCO falling film and ice storage systems give dairies a practical path to colder water, cleaner operation, and lower energy bills – without overbuilding refrigeration. Modular retrofits and hybrid designs let you scale with demand, protect product quality, and optimize total cost of ownership. For a tailored design and budgetary estimate, align system selection with your peak profiles, tariff structure, and hygiene requirements.

FAQ: Modern Dairy Cooling Solutions – BUCO Falling Film Chiller & Ice Storage Systems

1. What makes modern dairy cooling systems essential for dairy plants?

Modern dairy cooling ensures consistent product quality, food safety, and energy efficiency. Advanced systems such as BUCO falling film chillers and ice storage tanks supply reliable, near-freezing ice water 0.3°C-2°C ~ 32.5°F-35.6°F that stabilizes milk temperature quickly, prevents bacterial growth, and lowers operational costs.

2. How does a falling film chiller work?

A BUCO falling film chiller operates by letting a thin film of water cascade over vertical stainless steel heat-exchanger plates. Ammonia refrigerant evaporates on the reverse side, absorbing heat and producing ice water near 0.5°C ~32.9°F. The design provides excellent heat transfer – up to 2000 W/m²K – and resists freeze-related damage, ensuring dependable, low-maintenance cooling.

3. What is an ice storage (ice bank/ice maker) system, and how does it support dairy cooling?

An ice storage system acts as a thermal energy buffer. It builds ice during off-peak hours (low electricity rates) and melts it during production peaks to supply ice water. This decouples refrigeration capacity from process demand, enabling energy savings, stable temperatures, and flexible load management.

4. What are the main benefits of BUCO falling film and ice storage systems?

Key advantages include:

• Energy efficiency: Reduced compressor load and optimized night-rate power use.
• Hygiene: Direct ice-water cooling minimizes contamination risks.
• Flexibility: Modular configuration adapts to seasonal or line changes.
• Cost savings: Low ammonia refrigerant charge and minimal maintenance needs.
• Scalability: Retrofit-ready for plant expansions or upgrades.

5. Can existing dairy tanks be upgraded or retrofitted with BUCO systems?

Yes. Existing chilled-water or process tanks can be retrofitted with falling film chillers or ice makers/ice banks. This upgrade transforms conventional systems into high-performance, low-energy cooling units—proven effective in major dairy operations such as Nestlé and Danone plants worldwide.

6. What type of refrigerant is used, and is it environmentally friendly?

BUCO systems use ammonia (R717), a natural refrigerant with zero ozone depletion potential and excellent thermodynamic properties. The systems require only a fraction (⅛) of the ammonia used in conventional coil-in-tank designs, reducing environmental risk and compliance costs.

7. How hygienic are falling film chillers and ice banks?

Both systems use stainless steel cooling technology with smooth, fully accessible surfaces for easy cleaning and inspection. Direct ice-water cooling eliminates intermediate heat-transfer fluids, ensuring compliance with hygiene standards for dairy and food processing.

8. How can dairy plants save energy with these systems?

Plants gain energy savings through:

• Night-time ice generation with off-peak power tariffs.
• High-efficiency ammonia refrigeration cycles.
• Variable-frequency drives (VFDs) for pumps.
• Precise automation that balances ice-building and melting cycles for optimal load shifting.

9. How do falling film and ice storage systems compare in performance?

Feature	Falling Film Chiller	Ice Storage System
Cooling principle	Direct ice-water cooling	Stored ice energy
Outlet temperature	Stable 0.5°C ~ 32.9°F	0.5°C ~ 32.9°F during melt
Best use case	Continuous base load	Peak demand or redundancy
Key advantage	Precision temperature control	Energy and demand cost reduction

A hybrid system combining both technologies offers optimal flexibility and efficiency for multi-shift or high-volume dairies.

10. What maintenance is required?

BUCO systems are designed for low-maintenance cooling. Visual inspection and cleaning are straightforward thanks to open, accessible surfaces. Predictive monitoring through temperature and flow data helps detect scaling or performance drift early, ensuring minimal downtime.

11. What is the typical payback period for upgrading to BUCO technology?

Depending on energy tariffs, load profile, and retrofit scope, payback typically ranges from 2 to 4 years. Savings arise from lower energy use, reduced demand charges, smaller refrigerant volume, and extended equipment life.

12. How can I determine which cooling system fits my dairy operation best?

Assessment should consider:

• Cooling load (BTU/hr or kW) and daily demand cycles.
• Available space and existing infrastructure.
• Electricity tariff structure and peak rates.
• Required hygiene and temperature precision.

BUCO engineers or authorized partners can perform a site analysis to design a customized, scalable cooling solution.

13. Are BUCO systems suitable for other food and beverage sectors?

Yes. Beyond dairy, BUCO falling film chillers and Ice makers/Ice banks serve breweries, beverage bottling, and food processing industries requiring stable, hygienic, near-freezing process water.

14. What compliance standards do BUCO systems meet?

BUCO equipment is engineered in compliance with US ASME, EU Pressure Equipment Directive (PED), and relevant guidelines or hygiene, material safety, and thermal performance.

15. Where can I learn more or request a technical consultation?

To explore system sizing, retrofitting, or new installation options, contact a BUCO or HTT AG representative for engineering support and energy optimization analysis. System documentation and project references are available on their official websites.