Danfoss hot gas defrosting ensures reduced down time and increased profitability for Ananda Foods

Ananda Foods or Ananda Aqua Exports is located in the coastal city of Bhimavaram in Andhra Pradesh, and is one of the leading seafood companies in India that globally exports sea-caught as well as farm-raised aquaculture shrimps and prawns. It has state-of-the-art processing plants that process and freeze fishery products with traceability from farm-to-fork for food safety standards. Danfoss helped retrofit a hot gas defrost system that has led to a significant reduction in defrost time and approximately 75% improvement in productivity.

— 13 May 2015 By Danfoss India

Ananda Foods or Ananda Aqua Exports is located in the coastal city of Bhimavaram in Andhra Pradesh, and is one of the leading seafood companies in India that globally exports sea-caught as well as farm-raised aquaculture shrimps and prawns. It has state-of-the-art processing plants that process and freeze fishery products with traceability from farm-to-fork for food safety standards. Danfoss helped retrofit a hot gas defrost system that has led to a significant reduction in defrost time and approximately 75% improvement in productivity.

Ananda Foods employs state-of-the-art processing and freezing equipment with three plate freezers and an individual quick freezer (IQF) with two hardeners. Running at -40° C saturated suction temperature (SST) and 40° C saturated discharge temperature (SDT), the refrigerant is supplied to the evaporators using ammonia pumped over the feed system. Other freezing equipment includes flake ice machine for in-process requirements, water chiller for pre-chilling and freezers for storage.

Despite the high quality equipment, the key supporting process of refrigeration was not given due importance because of negligence and lack of awareness of the new systems. For example, defrosting the freezer evaporators and hardener was done using water defrost, which normally took a total time of one-and-a-half hours. They then decided to use hot gas defrost with a system that used a single-stage gas-powered solenoid valve in the wet suction line and a conventional back pressure control valve in the condensate return line using old-fashioned flanged stop valves. The current installation faced difficulties in maintaining a constant back pressure for defrosting. Due to the large variation in the pressure between the evaporators and the wet suction line, the opening of the single-stage solenoid valve in the wet suction after defrosts created severe and dangerous vibrations in the system, for which the inlet hot gas pressure and defrost back pressure had to be reduced—resulting in poor defrosting.

Danfoss studied the current defrost infrastructure and provided its unique solution using its ICF valve station and PMLX two-stage solenoid valve system, which enabled energy savings of the compressor through reduced run time and cleaner evaporator coils after defrost, resulting in effective heat transfer. The two-stage solenoid valves also reduced the shock on the system, improving the life of the components and piping system, enhancing system safety without affecting the defrost process. As a result, Danfoss’ unique hot gas defrost solution led to a significant reduction in defrost time per batch by up to 45 minutes. It is estimated that a 75% approximate improvement was realized in overall productivity compared to the traditional water defrost systems. Much to Ananda Foods’ delight, the Danfoss solution addressed all the key pain points by enabling reduced energy bills, reduced water consumption for defrost, and reduced labor work.

 

Be social Take part

Want to socialize with us?

Get to know us and take part in the conversation