Ice Water Cooling in Dairy Plants

Efficient milk cooling is vital for preserving quality, hygiene, and process stability in modern dairy production. BUCO ice water systems set new standards in industrial refrigeration, combining energy efficiency, operational reliability, and low refrigerant use. Compared to conventional coil-in-tank or plate heat exchanger systems, BUCO technology delivers sustainable, cost-effective, and environmentally responsible performance.

Why Modern Dairies Choose BUCO Ice Water Systems

Conventional coil-in-tank systems typically operate at evaporation temperatures around T₀ = -12 °C. In contrast, BUCO ice water systems achieve up to 30% higher compressor output at a much higher evaporation temperature (T₀ ≈ -2 °C). This allows most dairies to retain existing compressors while significantly improving cooling performance.

Energy demand rises by only about 5%, so existing motors remain adequate. In most cases, only evaporative condensers need to be resized to accommodate the enhanced capacity. The result is optimized energy efficiency without costly equipment replacements.

Cooling Principles in Dairy Processing

Milk undergoes multiple thermal stages – typically pasteurization followed by two cooling steps:

1. Pre-cooling with tap water
2. Final cooling with ice water produced by advanced industrial water chillers

Traditional dairies relied on ice bank tanks to accumulate ice for later melting. However, with today’s continuous 24-hour production and variable load peaks, modern plants require flexible, energy-efficient chiller-based systems that adapt dynamically to fluctuating demands.

Comparing Ice Bank Systems and Industrial Water Chillers

Traditional ice bank systems occupy large physical space, require low evaporation temperatures (T₀ = -10 °C to -15 °C), and hold high refrigerant volumes. Their heat transfer efficiency (K-value) drops as the ice layer thickens.

Plate heat exchangers were developed to minimize temperature differentials (~ 0 °C), but they can suffer from fouling and ice blockage in closed loops. By contrast, BUCO falling film chillers use an open evaporator design, ensuring superior hygiene, ease of cleaning, and mechanical reliability – ideal for high-capacity dairy operations seeking consistent, clean cooling performance.

Integrated Systems for Efficient Milk Cooling

The most effective dairy setups combine direct cooling from falling film chillers with energy storage in ice bank silos or chip ice systems. Depending on plant layout, both rectangular tanks and cylindrical silos can be integrated.

This hybrid concept covers the base load through direct cooling and uses stored ice capacity during peak demand. The stainless-steel open design ensures compliance with hygiene standards, simplifies maintenance, and achieves up to 80% less ammonia use. Reduced refrigerant content and efficient heat transfer translate to measurable energy and cost savings.

Advantages of Falling Film Chillers in Milk Cooling

Modern falling film chillers are at the heart of BUCO’s ice water systems. Key benefits include:

• Rapid milk cooling by ice water use to 0.5 °C
• High peak-load handling with stable performance
• Stainless-steel, corrosion-resistant construction for optimal hygiene
• Easy inspection, cleaning, and maintenance access
• Minimal fouling risk compared to plate heat exchangers
• Flexible integration into existing infrastructure

These advantages make falling film technology the benchmark for energy-efficient refrigeration in milk processing.

Glycol Chillers vs. Ammonia Systems in Dairy Applications

For dairies limited by ammonia regulations (≈ 4–5 tons NH₃), glycol chillers serve as a safe and efficient secondary system.
BUCO ice water systems minimize ammonia requirements – up to 80% less than traditional designs – keeping installations below regulatory thresholds while maintaining top cooling performance. This creates space for expansion and reduces compliance risks.

Energy Efficiency and Environmental Impact

BUCO systems combine optimized compressor utilization with lower operating costs and extended service life. Reduced ammonia levels lessen environmental impact and regulatory complexity. By leveraging off-peak electricity for ice production, dairies further cut operational expenses – making BUCO technology both economically and ecologically advantageous.

Technical Highlights of BUCO Ice Water Systems

• Optimized evaporation temperature: T₀ ≈ -2 °C for maximum efficiency
• Ice water output near freezing (≈ 0.5 °C) for rapid milk cooling
• Modular design for new builds and retrofits
• Open stainless-steel evaporators – hygienic and corrosion-resistant
• Up to 70% lower agitator energy costs
• 80% reduction in ammonia charge (NH₃)
• Combined falling film chiller + ice bank silo for base and peak load balance
• Variable-load operation with minimal maintenance

Conclusion: Next-Generation Cooling for the Dairy Industry

BUCO ice water systems merge technical innovation, energy efficiency, and hygienic design into a complete solution for milk processing plants. With improved cooling performance, reduced ammonia content, and sustainable operation, BUCO represents the next generation of industrial refrigeration for dairies seeking reliability, compliance, and profitability.

Contact us today for your customized BUCO ice water cooling solution.

FAQs: Ice Water Cooling in Dairies

What is an ice water cooling system?

An ice water system chills water to around 0.5 °C to rapidly cool milk after pasteurization or processing. BUCO designs achieve top performance with lower energy use and reduced refrigerant volume.

How does a falling film chiller work?

A falling film chiller spreads water evenly over vertical stainless-steel plates. A refrigerant evaporates inside the plates, efficiently absorbing heat and generating ice water at near-freezing temperatures – without ice blockages or mechanical strain.

Why choose BUCO ice water systems?

They deliver up to 30% higher cooling capacity with only a 5% energy increase and up to 80% less ammonia. Fully stainless-steel construction ensures top hygiene, durability, and easy maintenance.

When is an ice bank tank preferable?

Ice bank tanks suit plants with fluctuating demand, storing energy as ice for peak loads. For steady base loads, direct falling film chillers offer greater efficiency.

How energy-efficient are modern systems?

By operating at T₀ ≈ -2 °C, BUCO falling film systems generating ice water 0,5°C cut power use by up to 20% and enable nighttime ice production using T₀ ≈ -8°C low-tariff electricity.

What role does ammonia play?

Ammonia is a natural, highly efficient refrigerant. BUCO minimizes the required charge – often staying below legal limits – reducing environmental risk while maintaining maximum performance.

How does ice water cooling improve hygiene?

Rapid milk cooling to 2–4 °C halts bacterial growth. The open stainless-steel design simplifies cleaning and ensures high hygiene standards.

What maintenance is required?

BUCO systems are low-maintenance, thanks to their fully welded, seal-free stainless design. Routine inspection and water-quality monitoring suffice for long-term efficiency.

What industries benefit?

Beyond dairies, ice water systems serve beverage, food, and concrete cooling industries – anywhere precise temperature control is critical.

Is upgrading worth it?

Absolutely. Many dairies can reuse existing compressors, achieving higher efficiency, lower costs, and fast ROI with BUCO’s retrofit-ready solutions.