Maestrani in Flawil using modernised cooling technology
The chocolate manufacturer Maestrani is investing in the future and modernising its production. Customised CTAexklusiv chillers contribute to making even higher-quality chocolate. Using these chillers, a temperature range of 5 to 70 degrees Celsius can be produced—precisely and in an energy-efficient manner.
In brief
Temperature range of 5 to 70 degrees Celsius
Precise control of the complex system for supplying specific temperatures
A smart combination of cooling and heat generation
Energy-efficient operation
Distinctive flavour profile thanks to process cooling and heating
Those wanting to capture new markets have to continually develop distinctive flavour profiles in order to tickle customers’ taste buds. A new generation of conching machines—the key component of manufacturing chocolate—facilitates the precise control required of the individual steps in the production process. “At Maestrani, we’ve decided to invest in this process technology of the future”, explains technical director Carsten Engelhardt. “This allows us to innovate, improve the quality, and expand production output”, he continues.
The capacity was regularly supplemented by additional chillers.
More powerful and more efficient
A strategic decision with consequences: Initially, the energy and building services design had to be prepared for this step into the future. Because, alongside the boost in production, the new visitor centre also needs to be supplied with energy, energy requirements are now higher. The new chillers must be capable of producing a wide temperature range of 5 to 70 degrees Celsius. The new generation of conching machines, for example, requires the selective supply of cooling energy at a lower temperature level than the equipment previously in use. The supply of energy should also be made much more efficient.The key challenges:
Temperature range of 5 to 70 degrees Celsius
Precise control of the complex system for supplying specific temperatures
A smart combination of cooling and heat generation
Energy-efficient operation
The celebrated Minor and Munz chocolates are manufactured here.
Set on hydrofluroolefin (HFO) refrigerants
In the case of Maestrani, the green HFO refrigerant 1234ze was used, which complies with the Swiss Chemical Risk Reduction Ordinance (ORRChem). In terms of efficiency and functionality, it is the ideal solution. The modular design of the energy supply at Maestrani favoured the HFO refrigerant. Small ammonia-fuelled units would have been too expensive to purchase, and using an ammonia chiller would have proven uneconomical, as it could not have been utilised to capacity from the outset.
Installation
| Cold production (operating point 1) | Heat production (operating point 6) | |
| Cooling capacity | 222.6 kW | 183.7 kW |
| Power input: | 70.4 kW | 96.8 kW |
| Energy efficiency rating (EER) | 3.16 | 1.9 |
| Cold water inlet | 11 °C | 17 °C |
| Cold water outlet | 5 °C | 11 °C |
| Recooling (1) and Heating capacity (6) |
289.8 kW | 276.2 kW |
| Coefficient of performance (COP): | 4.12 | 2.85 |
| Hot water inlet | 35 °C | 60 °C |
| Hot water outlet | 45 °C | 70 °C |
| Refrigerant | R-1234ze | R-1234ze |
| Reciprocating compressor | 4 | 4 |
| Cooling circuit | 2 | 2 |