Review

District Cooling System as Cooling and Chilling

Method in Food Processing Industry
Clarence B.B, Abdurrahman N.I, Syahmi A.S
Keywords: Food processing, District cooling system, Chilling and cooling process, energy
sustainability
Highlight:

We study the common method of cooling and chilling process in food industry.

We study on the cost and energy consumed for chilling and cooling process.

District Cooling System technology and its concept.

How to apply district cooling system in food processing industry.

Advantage of district cooling system for food processing industry.

_________________________________________________________________________
Abstract:
District cooling is a centralized production and distribution of cooling energy where
chill water is delivered via an underground insulated pipeline, industrial and residential
building to cool the indoor air of a building in a district. In food processing industry
nowadays, most of the industry use conventional method which is air conditioning system for
cooling or chilling process. District cooling system has been introduced as a cooling or air
conditioning system for building in many develops country. However, district cooling system
is not widely used in food processing industry. Cooling process is one of the major
contributors to cost in food processing industry. Therefore, the district cooling system can be

introduced to industry because it can reduce the cost in term of energy consumption. The
concept that is used in district cooling is mass production of coolant (ice water) during night
time for usage during daytime. By processing ice during night time, the energy consume by
the system is much lower compared to conventional cooling system that required the
compressor to run all the time with lower COP (coefficient of performance) because of high
different of absolute temperature and relative temperature between sink and system. In
addition, the return stream (hot stream) can be utilized for heating process such as
pasteurization process, drying, etc. Beside this case study we are going to review and also
to purpose district cooling system as a new method for cooling and chilling in food
processing industry.

1.0 Introduction:
Cooling is a processing technique that is used to reduce the temperature of the food
from one processing temperature to another or to required storage temperature. Chilling is a
processing technique in which the temperature of a food is reduced and kept between -1oC
and 8oC. The purpose of both cooling and chilling is to reduce the rate of biochemical and
microbe changes in food in order to extend the shelf life of fresh and processed foods, or to
maintain certain temperature in process food, for example in fermentation and treatment of
alcoholic beverages. Other than that, cooling is also used to promote a change in state of
aggregation such as in crystallisation. Cooling is a process step in many food production
processes. Cooling of liquid food is commonly carried out to a heat exchanger (cooler) or by
cooling the vessels. The cooling medium in the cooler can be groundwater, water circulating
over a cooling tower or water (eventually mixed with glycol) which circulate via mechanical
refrigeration system (ice water). Cooling and chilling of solid food is carried out by contacting
the food with cold air, or directly with a refrigerant like liquid carbon dioxide or liquid nitrogen.
Chilling should decrease the temperature of heat processed food as rapidly as possible. The
chilling process should ensure the uniform and complete chilling of the food (-4). In all cases
during chilling processes, there must be adequate ventilation to prevent condensation on the
surface of products. The chilling process should achieve a target temperature in a specified
time in the food during every chilling treatment. This will ensure that the food, if consumed
within its shelf-life, and not exposed to contamination or temperature abuse during storage,
will not endanger the health of the consumer.
Malaysia located in tropical regions which the use of air conditioning is considered a
large proportion of Malaysias total electricity consumption. In 2010, for example, Malaysias
total electricity consumption of air conditioning accounts for 32% rather than residential

buildings accounted 72 per cent. Electricity demand in Peninsular Malaysia in 2010

continued to increase compared to 2009 by 7.8% from 94.748 GWh in 2009 to 102.139
GWh. Energy sales increased to 90.770 GWh, an increase of 8.8% when compared with
83.411 GWh in 2009 and power consumption of air-conditioning purposed during this period
increased an average of 5.8% from 14,245 MW in 2009 to 15,072 MW in 2010 and this
expected to increase for the following years (Energy Commissions of Malaysia, 2010). Since
the use of air conditioning believe will increase as our population and economic activity
continues to grow, so we need to take measures to improve energy efficiency, especially
proceed from the air conditioning system to save electricity demand through the use of
water-cooled air-conditioning systems, reduce greenhouse gas power station emissions to
protect the environment. In response to recent increases in energy prices, drivers are
examined for reducing energy use in the food industry, and areas where energy can be
saved through process optimization and equipment choice are identified. The cold chain is
essential in ensuring the safety, organoleptic quality, nutritional content and market value of
perishable foodstuffs from harvest to consumer. Worldwide it is estimated that 15% of the
electricity consumed is used for refrigeration. New and alternative refrigeration systems and
processes are examined and their potential for future exploitation evaluated.

2.1 Energy Consumption for Chilling and Cooling Process in Food Industry
In food processing industry, chilling or cooling process is one of the important unit
operations. Most of industrial that involves with biomaterial such as dairy industry, chocolate,
poultry and meat processing industry required chilling or cooling in their production line,
especially in storage. Other than storage, industry such as chocolate processing, dairy
product processing and brewing industry required controlled temperature environment to
maintain the quality of the product and for the process itself.
The following temperature guidelines, based on the federal Food and Drug
Administrations 2009 Food Code, apply at various stages of food preparation and serving.
Strictly maintaining these temperatures is particularly important when dealing with potentially
hazardous foods. These foods, which favour bacterial growth, include meat, poultry, eggs,
seafood, dairy products or potatoes and others. For storage of food material, refrigeration
temperature for air and food is below 3.3 oC and 5 oC respectively. For seafood, the storage
temperature is between -1 oC to 1 oC. For fresh produce, the temperature must be kept
around 5 oC to 7 oC. Temperature for deep chill and freeze food is -3.3 oC to 0 oC and -18 oC
respectively. When developing and implementing a heat-chill process, it should be designed
to eliminate or reduce to safe levels, pathogen(s) identified through risk assessment as the
most heat resistant, the most likely to outgrow during chilling, or presenting the greatest risk
as regards food safety.
To meet the requirement of controlled temperature, a huge amount of electrical
energy is required. Therefore, large amount of money is spent for electricity consumption.
The mean specific energy consumption, calculated over a daily production cycle, for air blast
cooling hot pie fillings at the factory was 173.3 kWh/tonne and ranged from a minimum of
143.2 kWh/tonne to a maximum of 208.2 kWh/tonne. Energy consumption of the

refrigeration system including the compressor, evaporator fans, and condenser fans and
defrost heaters ranged from a minimum of 99.1 kWh/ day to a maximum of 137.6 kWh/ day
with a mean of 120.5 kWh/ day over the sample production period. (Mark J. Swain, 2006)
In dairy product processing, milk cooling and water heating along with vacuum
pumps for milking are the major consumers of electrical energy in a milking centre. Milk
cooling and water heating together can account for 40 to 60% of the total dairy farm electric
use, and it is estimated that milking (through vacuum pumps) can take up to 15% of the
electric load in the State (Peebles and Reinemann, 1994; Edens et al., 2003). The chart
below shows the energy use by equipment in a summary of electricity audit on three
Teagasc Research Farms (J. Upton, 2010).

Chart 1: Summary of electricity audit on three Teagasc Research Farms (J. Upton, 2010).

The food industry is responsible for 12 % of the UKs industrial energy consumption
and uses over 4500 GWh/y of electrical energy. Approximately 99 % of the energy used for
refrigeration is electrical (Judith Evans, 2007). The UK food and drink sector has 15002000
manufacturing sites that are major users of refrigeration (Swain, 2006). Apart from
manufacturing where the majority of chilling and freezing occurs there are also cold storage
facilities where food is stored for variable times. There are also more than 100 000 retail
grocery outlets, 6400 supermarkets and large numbers of catering outlets that all use
refrigeration for maintaining the quality and safety of food. Refrigeration plants in UK
abattoirs were estimated to have consumed 270 TJ (75 x 10 kWh) of electrical energy worth
3.4 m during 1982 in chilling and chilled storage of carcass meat (Anon., 1985). A survey
carried out in 1984 estimated that 197 TJ were used for pig chilling (Gigiel, 1984) and, by
identifying factors contributing to high energy consumption, showed that energy reductions
of 60% were possible using existing technology.

2.2 District cooling system

The District Cooling System is a centralized cooling system for the large cold area to
provide cooling through district cooling centres concentrated, to the end user through a
cooling pipe network. Compared with decentralized cooling, central cooling area has high
energy efficiency, economy is good, easy operation and management advantages, is
important for the future development direction of the cooling technology.
Chilled water is produced in a central plant and distributed via a system of insulated
pipes that can run underground, on the surface or over the rooftops. Inside the buildings,

these transmission pipes are normally connected to a conventional air handling unit or fan
coil that allows the water to chill the air passing through. This means multiple chiller units
placed locally are no longer required. Once the required thermal energy has been extracted
from the cold water, this water is returned to the central plant to be re-chilled and recirculated through the closed-loop piping system. This cooling system is more flexible and
also operates with higher efficiency under all load conditions than traditional chillers [10].

District cooling is measured in refrigeration ton (RT) which it equivalent to 3.516 kW

per hour and RT is the unit measure of the amount of heat removed. RT is defined as the
heat absorbed by one ton of ice causing it to melt completely for 24 hours. District cooling is
the use of thermal energy for cooling production technology solution from power plants in a
secondary system. The cold production is transported by heat transfer fluid (usually water)
through a insulate pipeline network from the power plant to the consumer. Therefore, in the
district cooling system, an adequate system for cold generation system that functions as a
as a function of the thermal source is absolutely necessary [7].

In general, the district cooling system mainly consists of four parts: the heat rejection
system, the central plant, the distribution network and the consumer systems [6]. Central
power plant can be regarded as the core system.The heat energy required for the production
of district cooling systems can be prepared from various types of power plants (renewable
energy, waste energy, biomass, fossil fuels or etc.) and this characteristic place the district
cooling systems as a relevant technology for the building conditioning. However, to take
advantage of this great technology, it is highly recommended that no central power plants
based on fossil fuels and the production of heat are based on co-generation, renewable
energy, or waste valorization [7]. A storage tank and pumping system are required for the

transport of cold water from the point of production to final consumer.Typically, the direct
distribution of buried pipe systems is typically used to transport water (two pipes going and
back). Pipes made of carbon steel pipe shot-blasted, low conductivity polyurethane
insulation and high density polyethylene sheet, with a nominal flow velocity equal to 1.5 m / s
and DN 150-900 (mm) [7,8,9]. Distribution system equipped with a system to control other
properties of heat transfer fluids, water leaks, heat stress, and water quality.

The interface between the district cooling system and the factory or building cooling
system is usually referred to as the user station. Station users will usually consist of air
handling units, heat exchangers and cold water pipes in the building. A user station is
required in each building users to connect DCS distributed cold water pipe to the building. Instation users, devices known as heat exchangers installed to transfer heat between the cold
water supply of the DCS and the air conditioning system of the building users. User station
can be designed for direct or indirect connection to district cooling distribution system. With a
direct connection, cooling water circulates in the building area directly to terminal equipment
such as air handling and fan coil units, induction units, etc. The indirect connection using one
or more heat exchangers between the district and building systems. [12]

Fig. 1. A Network Concept of District Cooling System. [13]

Fig. 2. Arrangement of ice-storage tank and chillers. [7]

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2.3 Application of District Cooling In Food Industry

Why is District cooling?
2.3.1 Promote energy efficiency
District cooling is up to 10 times more efficient than conventional cooling technology.
Also different Greener energy sources like solar, natural gas geoexchange & its different
loop systems may enhance the energy efficiency. Centrally produced, and often based on
natural cooling from the cold bottom water of lakes, ground water, rivers, the ocean, or from
conversion of waste heat or bio energy through absorption technology, district cooling is
delivered to buildings via water at 6C in a closed, in-ground pipe system. After performing
the cooling service, the energy content of the now 16C water can be recycled for use in a
district heating system to provide heat and domestic hot water.
The main idea behind district cooling is to use local sources for cooling that would
otherwise be wasted or not used, in order to offer the local market a competitive and efficient
alternative to conventional products. Whereas the cogeneration through waste heat
recovery, power generation & water heating are the experimental physible areas adding
another feather in the cap of DCS [a].
2.3.2 Cost Savings
DCS and DHCS are more cost-effective and greener choices for heating and cooling.
Customers may enjoy lower initial capital investment from lower building and equipment
costs in the heating and cooling facilities. Customers may also enjoy lower operating costs
over its facilities lifecycle. From the journal,the electric bill are being calculated and being

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compare between DCS and ICS in Hong Kong. It consist of 3 parts which is demand charge,
energy charge and fuel clause.It show from the result that it found the energy of DCS is over
10% lower than that of ICS,indicating that DCS is very efficient economically. The cost
saving mainly lies in the energy[18].

Table 2: Table of electricity tariff structure under different uses in hongkong,Wenjie G. (2014)
Titile: Performance assessment of district cooling systems for a new development district at
planning stage, on 23rd May 2015.

Table 3: Table of cost of DCS and ICS under different users in Hong Kong, Wenjie G.
(2014), Title: Performance assessment of district cooling systems for a new development
district at planning stage,

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From the data, it can conclude that DCS is proven economically save cost in term of energy
cost, capital costs, lower operating and maintaining costs and easy payment of utility bills,
which leads to increase transparency of cost [19].
2.3.3 Reduction of global greenhouse effect potential.
District cooling is a local, sustainable solution to global cooling needs (Ravindra H. , 2013).
Base on the journal, it stated that roughly 40% in Europe are equipped with some kind of
climate for comfort cooling. District cooling makes possible the large-scale leveraging of
natural cooling and the delivery of this cooling in an energy efficient manner (Ravindra H. ,
2013). Most of the development countries a rapidly increase in using the district cooling
system. This district cooling system can give many benefit to environment, society and the
building or factories itself [16].
One of the benefits in term of the environment is that this district cooling system can reduce
the greenhouse effect by reducing it carbon footprint. From the basic standards term and
conditions assumed traditional design of conventional systems (HVAC) and DCS systems,
the Life cycle Assessment (LCA) attach the table that prove how the greenhouse effect can
be reduce and control.

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Table 1: Life Cycle Assessment(LCA) for using district Cooling, Ravindra H. Sarnaik(2013),
Title: District Cooling system, as HVAC system sustainable In India, retrieve from
ijiet.com/wp-content/uploads/2013/02/58.pdf, on 25th may 2015
LCA is a method that to evaluate the environmental burden associated with a product
process or activity by identifying and quantifying energy and material uses and releases to
the environment, and to evaluate and implement opportunities to influence environmental
improvement. The method assesses the entire cycle of product ,it process and activities,
encompassing extracting and process material; manufacturing transporting and distribution;
use, reuse and maintenance; recycling and final disposal ( the society of environment
Toxicology and chemistry, 1993) .
District Cooling System reduces life-cycle carbon footprint, particularly the carbon
footprint from the repair and operational carbon footprints (50 years). However, District
Cooling System has the higher carbon footprint from initial (4 Years) and disposal stage (1
year) that required more carbon mitigation measures that reduces the footprint. Therefore,
from the whole life-cycle perspective, we can draw the conclusion that the District Cooling
System can reduce the Global Warming Potential (GWP) in comparison to conventional
HVAC [16]. Base on the EcoHeatCool (2006), the air pollutants of district cooling are related
to the final energy consumption of the building and are not related to the primary resource
factor, because renewable fuels emit air pollutants as well as fossil fuels [17].
2.3.4 Health Benefit
Reductions in health effects associated with supply and consumption of utility fuels are
predicted for the district-cooling scenarios (Table 4).

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Table 4: Table of Reduced annual environmental effects for the district cooling scenarios,
Donald R. H. (1996), title: environmental and health benefits of district Cooling using utilitybased cogeneration in Ontario, Canada
Greater health benefits accrue as a result of reduced coal consumption than as a result of
reduced uranium consumption, due to the greater health effects inherent in the coal fuel
cycle. Reductions in ecological effects are also predicted for the district-cooling scenarios
(Table a). The reduced impact from Lake Acidification and from crop losses associated with
each of the scenarios is a result of reduced coal consumption, air pollution and acid
deposition. Greater ecological benefits accrue As a result of reduced coal consumption than
as a result of reduced uranium consumption, since significant Ecological effects have not
been demonstrated in association with nuclear power-plant operation. Local ecological
effects have been associated with both coal and uranium extraction. However, no attempt
has been made to quantify these specifically as a function of fuel production. The most
significant extraction effects are related to acid mine drainage, which is a greater problem in
coal mines than in uranium mines. The reductions in human health and ecological effects
that can be realized through the scenarios translate into reduced monetary costs to society,
once a monetary value is placed on the effect. Based on estimated monetary values for lives
lost, fish-yield loss and crop-yield loss, the reduced costs to society are shown for each
district-cooling scenario (Table x). Greater health and environmental cost savings accrue to

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cogeneration as a result of reduced coal consumption than as a result of reduced uranium

consumption. Depending on the scenario considered, annual savings range from $0.6 to
$2.7 million, as compared to a current base-case health plus environmental annual cost of
approximately $122 million without district cooling [d].

Table 5: Table of Reduced annual environmental effects for the district cooling scenarios,
Donald R. H. (1996), title: environmental and health benefits of district Cooling using utilitybased cogeneration in Ontario, Canada,

Table 6: Table of Reduced annual environmental effects for the district cooling scenarios,
Donald R. H. (1996), title: environmental and health benefits of district Cooling using utilitybased cogeneration in Ontario, Canada,

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3.0 Recommendation
From the journals review thaw we have study, we would like to propose district
cooling system (DCS) for application in food processing industry especially in industrial zone
and processing plant. From the journal, we learn that DCS give advantage to the industries
in term of energy efficiency where we can optimize the energy consumption, and minimize
he cost for energy and promoting green earth.
In term of energy efficiency, DCS is 10 times more efficient compared to ordinary
HVAC or air conditioning system. In food processing industry; for example diary product
industry, there are many equipment and unit operation involving heating and cooling. There
are two stream in DCS which is hot stream and cold stream. Therefore, besides using the
cold stream, DCS provide heat energy for unit operation that involve heating process; for
example pasteurization. Other than that, DCS is a centralized cooling system which means
the energy used for cooling is more efficient compared to air conditioning or HVAC that use
local cooling system. Besides that, DCS not only be used for cooling or chilling in
processing, it also can be used to cool the management office, control or server room, and
many more. This means that, the industry do not need too many separate cooling system for
particular purpose.

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By using DCS, the food processing industry also can save cost in term of production
cost. From journal, we learn that the energy use by using DCS for cooling the building is
much lower in Hong Kong. Therefore, when apply to food processing industry; we believe
that the system also will reduce the cost of energy for cooling process. By processing ice
(coolant) during night time, the energy consume by the system is much lower compared to
conventional cooling system that required the compressor to run all the time and lower COP
(coefficient of performance) because of high different of absolute temperature and relative
temperature between sink and system. By using DCS system, the electricity use also can be
managed. This mean we can produce ice during night (12am-5am) and can avoid from the
peak hour electricity tariff. The table below shows the cost and power consumption for
cooling and heating process in dairy product processing.
Process

Power

Average

Consumption

operation per day

kw/h

hour

of Electricity
Tariff

Estimated cost
(RM)

Per kW

Heating

48.24

16 hour

0.38

294.76

Cooling

57.57

24 hour

0.38

525.04

DCS also promote to green environment. Nowadays, the industries are more
sensitive towards the environment. Not only focusing to make more profit, the industry also
must focus on the sustainability of energy and conserving the earth. By using DCS, the
industry also help to promote green environment and conserve earth by reduce the amount
of gases release to the atmosphere. DCS reduces life-cycle carbon footprint, particularly the
carbon footprint from the repair and operational carbon footprints (50 years).

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4.0 Conclusion
As a conclusion, we would like to propose district cooling system to be used for
cooling system in food industry. This is because, district cooling can reduce the cost for
production, increase energy efficiency and promote to sustainability and green earth.
Although there is not much study have been done for application of district cooling system in
food industry, we believe that district cooling system benefits the industry in long term. Other
than that, we proposed that more research to be for application of district cooling in food
industry to discover more potential of the system.

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