Refrigeration typically accounts for more than 40% of electricity consumption in dairy processing, making cooling system efficiency one of the biggest influences on operating costs. Yet while investment is often focused on refrigeration plant and production equipment, the condition of the cooling system itself is frequently overlooked.
Hydratech works in partnership with many of the UK's leading dairy processors—including Arla, Müller, Saputo and Rodda's—to improve cooling system efficiency, reliability and long-term performance. Combining advanced heat transfer fluids and specialist engineering services, Hydratech helps operators reduce energy consumption, increase productivity and minimise unplanned downtime.
At a glance
Industry
Dairy Processing
Customers
Leading UK dairy processors including Arla, Müller, Saputo & Rodda's
Challenge
Declining cooling performance, rising energy consumption and system contamination
Hydratech solution
Result
17% reduction in cooling energy consumption
The challenge
Refrigeration is one of the largest consumers of electricity within a dairy processing plant. As cooling systems age and production demands evolve, hidden issues can gradually reduce efficiency, increase operating costs and affect long-term reliability.
Hydratech works alongside dairy processors to identify and resolve these issues before they impact productivity, helping customers improve cooling system performance through engineering expertise, advanced heat transfer fluids and proactive system management.
Common issues Hydratech identify
Across dairy processing plants, Hydratech regularly identifies issues including:
- Fluid degradation
- Process contamination
- Reduced heat transfer efficiency
- Increased pumping energy
- Corrosion
- Biological fouling
- Hydraulic inefficiencies
- Higher operating costs
- Increased maintenance requirements
Left untreated, these issues gradually reduce cooling system performance while increasing energy consumption and operational risk.
Customer success story
Significant reduction in cooling energy consumption
A major UK dairy approached Hydratech following concerns around declining cooling system performance and increasing energy consumption.
Following Hydratech's on-site sampling and comprehensive in-house laboratory testing, a number of issues affecting cooling system performance were identified, including:
- Milk fat contamination within the chilled water system
- Degrading glycol condition
- Reduced heat transfer efficiency
- Hydraulic inefficiencies
- Increased refrigeration load
Hydratech used these findings to develop a targeted programme of remedial works, engineering improvements and an upgrade to Coolflow DTX®® to optimise cooling system performance, improve reliability and reduce energy consumption.
The programme included:
The results
Following completion of the programme, the dairy reported:
- 17% reduction in energy consumed by coolant circulation pumps and process cooling systems
- Reduced refrigeration compressor loading
- Shorter compressor running times
- Improved cooling system performance
- Increased operational reliability
- Extended equipment life
To preserve these gains, the dairy now benefits from an ongoing Planned Preventative Maintenance programme delivered by Hydratech Services Division (HSD).
More than heat transfer fluids
Hydratech is more than a manufacturer of heat transfer fluids. Through its dedicated Services Division, the company combines chemical engineering, mechanical engineering and practical site expertise to help dairy processors commission, maintain and optimise closed-loop cooling systems throughout their operational life.
By integrating advanced heat transfer fluids with specialist engineering services and its Fluid Monitoring Program (FMP), Hydratech helps customers improve cooling efficiency, reduce operating costs and maintain reliable system performance.
Whether supporting the commissioning of a new cooling system or improving the performance of an existing process cooling system, Hydratech's engineering teams work alongside site operators, consultants and contractors to identify hidden inefficiencies, implement practical improvements and protect long-term asset performance.
Services include:
- Heat transfer fluid selection and optimisation
- Fluid Monitoring Program (FMP)
- Pre-commission cleaning and chemical flushing
- Cooling system commissioning and recommissioning
- System balancing and performance optimisation
- Corrosion, inhibitor and water chemistry management
- Biological contamination monitoring and remediation
- Side-stream filtration solutions
- Planned Preventative Maintenance (PPM) programmes
- Reactive engineering support and ongoing system optimisation
This integrated approach helps dairy processors reduce energy consumption, improve thermal performance, extend equipment life and minimise the risk of unplanned downtime.
Building more efficient & reliable dairy cooling systems
As energy costs continue to rise and production efficiency becomes increasingly important, cooling system optimisation offers one of the most effective opportunities for improving operational performance.
Whether identifying hidden energy losses, improving heat transfer efficiency, extending equipment life or reducing unplanned downtime, Hydratech helps dairy processors achieve measurable improvements through engineering expertise, advanced heat transfer fluids and long-term system management.
Ultimately, effective cooling is about far more than maintaining temperature. It's about protecting productivity, reducing operational risk and ensuring the entire dairy process operates as efficiently and reliably as possible.
FMP: Discover how your cooling system could perform better
Hydratech's Fluid Monitoring Program (FMP) provides an ongoing assessment of cooling fluid condition and overall system performance, helping identify hidden issues before they impact efficiency, reliability or production.
The programme includes:
- Comprehensive laboratory fluid analysis
- Freeze protection verification
- Corrosion and inhibitor assessment
- Biological contamination testing
- Heat transfer fluid performance monitoring
- Cooling system performance review
- Expert recommendations to improve efficiency and reliability
By taking a proactive approach to fluid monitoring, dairy processors can maintain peak cooling performance, extend equipment life and reduce the risk of costly unplanned downtime.
If you're looking to improve the efficiency, reliability and long-term performance of your dairy cooling system, contact Hydratech today to find out how the Fluid Monitoring Program (FMP), engineering expertise and advanced heat transfer fluids can help optimise your cooling system.
