Bem Brasil gains efficiency in the potato freezing process by opting for a modern line of valves and controls

Bem Brasil Alimentos is the first Brazilian manufacturer of frozen french fries. The company combines its experience in growing selected potatoes with a modern industrial production structure

One of its key differentiators is the guaranteed excellence of its products thanks to its industrial process. In other words, the strict control of the production process is capable of offering top-quality products. To maintain this mission, control of the refrigeration system plays a crucial role.

To obtain control of the refrigeration system, Bem Brasil sought equipment and technology solutions by Danfoss that were more modern and efficient. By using automatic valves and controls, which result in more efficient operating conditions, Bem Brasil achieved energy savings of approximately 12% when compared to conventional systems, in addition to safer operations.

We searched the market for a supplier that could offer state-of-the-art technology, which at the same time would bring us safe and effective operational confidence, with technical assistance that was qualified and present whenever needed

commented Célio Zero, Chief Operating Officer of Bem Brasil Alimentos.

Because it is an integral plant, involving freezing and storage of natural products, Bem Brasil needed all the automatic valves and controls for the refrigeration plant, for both the machine rooms and the valve stations for temperature control, defrosting chambers, and continuous freezing tunnels

explained José Faria, Engineer at Frio Plus Refrigera??o, Danfoss’ technical commercial representative.

Every industrial refrigeration system is designed from the get-go in a unique way, in which the needs of the project and its equipment are assessed first, followed by a search for the best technological solutions.

Among the devices implemented, for the liquid separators, the proportional feeding system was used, using ICM motorized expansion valves, AKS 4100 level transmitters, and EKE 347 electric level controllers. The advantages of proportional feeding include the stable control of ammonia levels and reduced energy consumption of the compressors, as there are no abrupt increases in pressure.

In the valve stations, two types of technologies were used, having been chosen according to their refrigerating capacity. For smaller-capacity tunnels, the concept of defrost control by condensate drainage was applied. In this case, ICF-type single-block valves were used with the ICFD module, a type of oat that allows only the liquid to return to the separator, preventing the migration of superheated steam, which would require additional work from the compressors.

In stations with greater capacity, the soft defrost concept was applied, which starts with an injection of hot gas limited to 15%, followed by a release of the total gas flow. This provides more safety and allows users to expedite the process in the evaporator draining phase. Consequently, it was possible to reduce the defrost time while increasing the level of operational safety.

To complete these automatic defrosting systems, new EKE 400 defrost controllers dedicated to each station were assembled. These controllers were developed based on the characteristics of Danfoss valves and have a program ready to command various types of defrost processes, being interconnected to Bem Brasil’s PLC system for monitoring and changing settings. because the EKE 400 controllers are fixed to rails inside the electrical panels, the MMIGRS2 displays (remote HMI) were mounted on the panel door, concentrating several EKE 400 controllers and facilitating the monitoring of the entire system operation.

For the success of this project, one crucial aspect was the combination of the very latest in terms of valves and controls in industrial refrigeration and the proximity to the Bem Brasil engineering team, which pursues excellence in its refrigeration processes

concluded Faria.

Learn more about our solutions:

• ICM Flexline? motor valves - https://www.danfoss.com/en/products/dcs/valves/control-and-regulating-valves/icm-flexline-motor-valves/
• ICAD B Motorized valve control - https://www.danfoss.com/en/products/dcs/valves/control-and-regulating-valves/icadb/
• ICFD defrost module - https://www.danfoss.com/en/products/dcs/valves/control-and-regulating-valves/icf-flexline-valve-station/icfd-defrost-module/
• EKE 400 Evaporator controller - https://www.danfoss.com/en/products/dcs/electronic-controls/evaporator-control-eke-400/
• EKE 347 Electronic valve controller - https://www.danfoss.com/en/products/dcs/electronic-controls/electronic-valve-control-eke-347/
• AKS 4100 Liquid level sensors - https://www.danfoss.com/en/products/dcs/sensors-and-transmitters/liquid-level-sensors/