Modern dairy processing facilities depend on reliable, high-capacity industrial refrigeration systems to maintain product quality, meet food safety standards, and support continuous production. When an existing plant transitions to ultra-pasteurized processing, refrigeration demands increase significantly. Equipment must handle higher loads, tighter temperature tolerances, and expanded operational requirements.
In 2018, Louis A. Roser Company completed a large-scale industrial refrigeration retrofit at a dairy processing facility in Salt Lake City, Utah. The project involved modernizing ammonia refrigeration and glycol cooling systems to support ultra-pasteurized organic product production. With headquarters in Salt Lake City and service coverage across Utah, Idaho, California, Colorado, Nevada, Oregon, Washington, and Montana, Louis A. Roser Company provides industrial refrigeration installation, system upgrades, and food processing plant retrofits throughout the western United States.
Project Background: Converting a Dairy Facility to Ultra-Pasteurized Production
The facility was originally designed for traditional dairy processing. After acquisition, the plant underwent extensive remodeling to accommodate ultra-pasteurized production lines. Much of the interior infrastructure was removed, and new processing equipment was installed to meet updated operational standards.
Ultra-pasteurization requires precise temperature control and dependable cooling capacity. Any fluctuation in refrigeration performance can impact product integrity, compliance, and throughput. Because of this, the refrigeration system required a comprehensive redesign rather than minor adjustments.
Louis A. Roser Company worked in coordination with the general contractor and engineering team to ensure that the new ammonia refrigeration system and glycol cooling system aligned with process loads, building layout changes, and commissioning schedules.
Industrial Refrigeration Scope of Work
This complex retrofit involved multiple system components, inspections, and new equipment installations.
Heat Exchanger Inspection and System Evaluation
Before integrating existing components into the upgraded system, our team opened and performed ultrasonic testing inspections on shell and tube heat exchanger tubes. This process confirmed material integrity and ensured the equipment could safely operate within the redesigned ammonia refrigeration system.
Thorough inspection at this stage reduced risk during start-up and protected long-term system performance.
New Glycol Cooling System Installation
A new glycol cooling system was installed to support updated process loads throughout the facility. Work included:
- Installation of new piping distribution across multiple production areas
- Installation of a new flooded plate and frame heat exchanger package
- Installation of a new glycol storage tank and pump system
The glycol system plays a critical role in secondary cooling loops within food processing facilities. Proper piping layout, pump sizing, and heat exchanger selection were essential to maintaining consistent temperatures for ultra-pasteurized production.
Ammonia Refrigeration System Upgrades
Ammonia refrigeration remains one of the most efficient and widely used solutions in large dairy and food processing facilities. For this project, Louis A. Roser Company installed and upgraded major ammonia system components, including:
- Installation of new ammonia compressors
- Retrofit of an existing recirculator
- Addition of a liquid ammonia transfer pump
- Installation of a new ammonia diffusion tank
The new compressors increased system capacity and improved reliability under higher thermal loads. The recirculator retrofit allowed integration with updated piping and equipment. The liquid ammonia transfer pump enhanced system flexibility and operational control. The ammonia diffusion tank supported safe and stable system operation.
These upgrades were carefully coordinated with other trades to align with construction sequencing and production deadlines.
Heat Rejection and Cooling Water Systems
Efficient heat rejection is critical in any industrial refrigeration system. To support the updated ammonia system, the project included:
- Installation of a new cooling water storage tank and pump system
- Installation of new fluid coolers
- Installation of a new evaporative condenser
The evaporative condenser plays a central role in removing heat from the ammonia refrigeration cycle. Proper installation and integration were essential to maintaining efficiency and preventing bottlenecks during peak production.
The new cooling water and fluid cooling systems were designed to support long-term durability and stable operation under demanding processing conditions.
Controls Coordination and Safety Compliance
Industrial ammonia refrigeration systems require strict compliance with safety regulations, particularly under Process Safety Management and Risk Management Program standards.
Louis A. Roser Company assisted with refrigeration controls changes and coordination to ensure proper communication between compressors, condensers, pumps, and monitoring systems. During commissioning, our team provided PSM and RMP start-up assistance to help the facility transition safely into operational status.
Start-up is one of the most critical phases of any industrial refrigeration retrofit. Proper testing, documentation, and coordination protect both personnel and equipment while confirming system readiness.
Project Challenges and Execution
Dairy plant remodels introduce several challenges that require experienced industrial refrigeration contractors:
- Tight construction schedules with multiple trades working simultaneously
- Integration of new ammonia refrigeration equipment into an evolving facility layout
- Maintaining compliance with ammonia safety regulations
- Ensuring production readiness within strict deadlines
This project required detailed planning, proactive communication, and precise field execution. System components had to be installed and commissioned within a compressed timeline, without compromising safety or performance.
Through coordination and disciplined installation practices, the refrigeration system was delivered on schedule and aligned with production goals.
Results: Reliable Refrigeration for Dairy Processing
The completed industrial refrigeration system provided the capacity and reliability required for ultra-pasteurized dairy production. Upgraded ammonia compressors, improved glycol distribution, and enhanced heat rejection systems created a stable operating environment designed for continuous processing.
Beyond project completion, Louis A. Roser Company continues to support the facility with ongoing industrial refrigeration service and maintenance. Long-term partnerships are a core part of our approach, especially in food and beverage environments where uptime and system integrity are essential.
Industrial Refrigeration Services Across the Western United States
Louis A. Roser Company provides comprehensive industrial refrigeration services for dairy processing plants, food manufacturing facilities, cold storage operations, and industrial facilities, including:
- Ammonia refrigeration system installation
- Industrial refrigeration retrofits and system modernization
- Glycol cooling system design and installation
- Evaporative condenser and fluid cooler installation
- Heat exchanger inspection and system upgrades
- Refrigeration controls coordination
- PSM and RMP compliance support
- System commissioning and start-up assistance
With headquarters in Salt Lake City, Utah, and service throughout Utah, Idaho, California, Colorado, Nevada, Oregon, Washington, and Montana, Louis A. Roser Company delivers industrial refrigeration solutions built for safety, efficiency, and long-term performance.