Engineering Precision in Motion:
How CB Refrigeration Delivered a Technically Complex Chiller Overhaul at Suntory’s Live Manufacturing Plant.
When Suntory, a major global drinks manufacturer, faced critical issues with aging chillers in one of its busiest production facilities, it needed more than just an equipment swap; it required a highly engineered, zero downtime solution. The challenge? Replace
existing absorption chillers on the third floor of a live production site with limited space
and no tolerance for failure (as this system was extremely vital to maintain continuous
operations in all plant production areas).
CB Refrigeration, a leading industrial refrigeration specialist, was selected to deliver this design and build project, requiring intense co-ordination, mechanical ingenuity and flawless technical execution. Every element of the solution demanded absolute precision.
Project Challenges
From the very outset of the project, several challenges were identified.
- Limited Power Supply. The existing aging absorption chillers were steam driven coolers and so the maximum cooling capacity was limited to the available power. This meant that extremely efficient plant and system design was necessary.
- Limited Space. The existing absorption chillers were located in an open plan area on the third floor of the building. As the new chillers would be ammonia chillers, a new plant room had to be constructed complete with leak detection, audio and visual alarms and plantroom extract.
- Noise and vibration restrictions. The site had some close residential neighbours and Suntory were concerned that noise from the new plant could attract noise complaints. Also, because the plant was located on the third floor, there were concerns that any vibration could resonate through the rest of the building.
- Production was not to be affected. This would require careful planning, liaising closely with the client and delivering the project in two stages.
- Four separate refrigeration companies had been invited to tender for the project. Although this presented a challenge, it also presented an opportunity. Because no specification had been issued, it gave CB a blank sheet of paper to put forward the best design possible, and a design that addressed all of the challenges.
- Time scales were extremely tight. Four 1,300kW ammonia systems (5,200kW total) delivered in ten months. This included, detailed design, customer approval, plant and equipment procurement, installation and commissioning in two phases, and handover complete with all documentation, test certificates, drawings and O&M manual.
After a short period of time, two of the four contractors that were asked to tender had either been eliminated or dropped out due to the challenges.
This left CB and one other major national industrial contractor in the running. Our solution was to adapt the existing infrastructure from two of the absorption chillers to accommodate four Sabroe SMC 116L VSD semi-hermetic ChillPACs. The Sabroe semi hermetic ChillPACs were chosen because of their incredible efficiency delivering 1.3mW of cooling duty each for just 214kW of power input each. The efficiency of the Sabroe units solved the challenge of the limited power supply on site and the small footprint also went a long way to solve the challenge of the limited plant room area.
After putting forward the best engineered solution and at the best cost, CB were duly awarded the contract and given the go ahead to proceed with the full system design.
The latest technology was employed during the design process. The existing area was 3D laser scanned and a virtual 3D model was constructed of the new installation. All new pipework, components, extract ducting, electrical works, steel supports and service lifting beams were draw onto the new model. Clashes between any of the services were identified at the modelling stage and so pipes, steels etc could be moved, sometimes with only millimetres to spare.
Thanks to the small footprint of the Sabroe ChillPACs and the clever use of laser scanning and 3D modelling, everything was fitted into the plant room like a game of tetras but still leaving room to easily service everything.
Suntory’s chiller system was nearing end of life, leading to efficiency and reliability concerns that posed serious risks to temperature sensitive beverage production. The site, however, presented a multitude of complications:
- Existing equipment had to be dismantled and removed from the third floor of a building with limited access
- The working area was extremely space restricted, requiring precision planning
- Live production operations had to continue uninterrupted throughout the project
- The plant’s legacy absorption systems required compatibility with any new installation
A complete CDM managed project was required, including structural adjustments, M&E upgrades and new safety infrastructure; all within a tight timeframe and with no option for site shutdown.
Technical Solutions & Project Execution
CB Refrigeration led with a full design and engineering review, identifying a suitable, high efficiency chiller, capable of a 30 to 50 year lifespan. Sabroe SMC 116L VSD semi-hermetic ChillPACs were selected for their efficiency, small footprint and compatibility with existing infrastructure. Four new Sabroe ChillPACs were installed giving 5.2 mega Watts of cooling in total.
“THIS WAS A HIGH RISK, HIGH COMPLEXITY JOB WHERE EVEN MINOR MISCALCULATIONS COULD HAVE SERIOUS CONSEQUENCES. SUCCESS DEPENDED ON GETTING EVERY DETAIL RIGHT.”
Tom Hannaby, Managing Director, CB Refrigeration
Precision Engineering: Refrigerants, Ammonia & Dimensional Constraints
A major challenge lay in ensuring the new system operated safely and efficiently. R717 (ammonia), known for its high performance and efficiency, however, being a B2L safety group refrigerant, both EN378 and DSEAR applied to the installation.
Therefore, CB Refrigeration undertook the complete plantroom design including leak detection, plantroom extract system, safety shower, plantroom safety signage and staff training.
Equally important was the dimensional accuracy. Severe space restrictions required detailed planning on the positioning of the ChillPACs, pipe routes, lifting beams, cables and extract ducting whilst allowing enough room so that everything was easily accessed and serviceable.
The engineering team used the latest laser scanning technology to develop a highly accurate 3D model, combining mechanical layouts with real time measurements of the building.
This model was instrumental for both fabrication and installation, ensuring that there were no clashes or misalignments.
“THIS HAS BEEN A VERY CHALLENGING PROJECT, BUT ALSO A VERY REWARDING AND ENJOYABLE PROJECT. IT IS GREAT TO BE ABLE TO DELIVER SUCH A COMPLEX INSTALLATION TO THE
CUSTOMER’S COMPLETE SATISFACTION.”
Nick Franzen, Technical Consultant, CB Refrigeration
Live Site Implementation: Phased Delivery with Zero Downtime
To ensure business continuity, CB Refrigeration provided a temporary interim chiller system, keeping operations stable while the legacy system was decommissioned.
Old equipment was carefully dismantled and the new chillers were craned and manoeuvred onto the third floor through tight service routes.
CB Refrigeration installed all mechanical and electrical infrastructure and integrated the new chillers with the main headers inside the building.
Despite some delays beyond the control of CB refrigeration, work was completed on time by utilising additional labour and working extended hours.
Also, key to the success of the project was co-operation with a number of specialist delivery partners. Heavy plant movement was carried out by a specialist lift and shift company, the stainless-steel pipework was installed by specialist coded welders to name just two. power supply on site and the small footprint also went a long way to solve the challenge of the limited plant room area.
After putting forward the best engineered solution and at the best cost, CB were duly awarded the contract and given the go ahead to proceed with the full system design.
“THIS WAS NO ORDINARY INSTALLATION, EVERYTHING FROM PIPEWORK TO EXTRACT DUCTING, LIGHTING, LIFTING BEAMS,CABLES AND LEAK DETECTION HAD TO BE COORDINATED. TEAMWORK WAS EVERYTHING.”
Tom Hannaby, Managing Director, CB Refrigeration
Compliance, Safety & Post Installation Support
Safety was integral to the project. CB Refrigeration managed all CDM responsibilities, constructed a new hazardous substance shower zone and conducted thorough risk assessments for ammonia exposure and system pressure testing. CB Refrigeration also provided training to Suntory employees, qualifying them in ammonia awareness and outlining operational procedures around the new system. A business management system with real time energy analytics was installed to help monitor efficiency and cost performance.
“FOR US ONE OF THE KEY REQUIREMENTS OF THE NEW CHILLED WATER PLANT WAS HIGH EFFICIENCY TO HELP US MEET OUR SUSTAINABILITY TARGETS. ELECTRICAL METERS WERE INSTALLED ALONG WITH HEAT METERS ON EACH CHILLER. THIS DATA HAS BEEN CRITICAL FOR US TO ENSURE WE ARE ABLE TO OPTIMISE PUMP CONTROL AND ENSURE THAT WE ARE ABLE TO MEET OUR KPI’S ON CHILLED WATER DELIVERY TO THE PRODUCTION LINES. ALL THIS DATA IS FED BACK INTO OUR EXISTING BMS SYSTEM AND FROM THIS WE ARE ABLE TO SEE THAT THE COP VALUE OF THE NEW PLANT IS BETWEEN 6.3 – 7.1”
Scott Hale, Reliability Engineer, Suntory
Project Results
- Seamless chiller transition with no production downtime
- Ammonia refrigerant system calculated, installed and commissioned with zero leakage
- New chillers integrated with absorption chillers infrastructure
- All systems delivered on time and within budget
- Employees trained and certified in hazardous substance awareness
- Installation of real time monitoring tools and emergency shower facilities
- Fully compliant with CDM and safety regulations
Collaborative Execution
CB Refrigeration’s success on this project was underpinned by its collaborative ecosystem of delivery partners, all of whom were tightly integrated into the project management structure. From structural engineers to ducting specialists, the combined effort ensured every technical and safety milestone was met with precision and confidence.
“WE ALWAYS SAY IT TAKES A TEAM TO DELIVER A PROJECT THAT DEMONSTRATES EXCELLENCE IN ENGINEERING; AND THIS WAS THE PERFECT EXAMPLE OF THAT IN ACTION.”
Tom Hannaby, Managing Director, CB Refrigeration
Conclusion
This project showcased CB Refrigeration’s ability to deliver technically complex, time sensitive refrigeration solutions in the most challenging environments. By blending technical expertise, precision engineering and flawless execution, CB Refrigeration helped Suntory future proof their operations; without ever switching off the production line.
The engineering team used the latest laser scanning technology to develop a highly accurate 3D model, combining mechanical layouts with real time measurements of the building. This model was instrumental for both fabrication and installation, ensuring that there were no clashes or misalignments.
Customer Verdict – Tom Moseley, Project Manager, Suntory
“I would recommend CB Refrigeration for their excellent work on a recent project. From start to finish, their team demonstrated professionalism, technical expertise, and a strong commitment to achieving the objectives of the project.
The project was completed on time and within budget, with a proactive and pragmatic approach to problem solving. Communication throughout was clear and responsive, making the process as smooth as possible, particularly around critical phases of the project where disruption to the ongoing factory production was very closely coordinated and resulted in no lost production time due to the project.
It was a pleasure working with them and I would not hesitate to engage their services again for any future refrigeration projects.”
