COOLING PROCESS OPTIMIZATION & AIR DISTRIBUTION UPGRADE

Cereal Manufacturing Plant   Montreal, Quebec

Process Engineering • Thermal Analysis • Airflow Optimization • Fan System Design • Fabrication & Installation • Process Validation • Low-Capex Improvement

~$55,000 REFRIGERATION INVESTMENT AVOIDED

Process Analysis | Custom Air Distribution System | Physical Implementation | Performance Validated

ExtremeTech was initially engaged to evaluate and implement a refrigerated cooling solution with an expected capital investment of approximately $55,000.

Before proceeding with the refrigeration system, we evaluated the existing process to determine whether refrigeration was actually necessary. Product temperatures, cooling requirements, airflow, rack configuration, fan capacity and air distribution were studied under real production conditions.

The analysis showed that the primary limitation was not a lack of refrigeration capacity, but inefficient airflow distribution through the product racks.

Instead of proceeding with the proposed refrigeration investment, we designed, built and implemented a new fan and air-distribution system using properly selected fans, directional flaps, baffles and airflow guides to deliver cooling air more effectively across each tray.

The required cooling performance was achieved at a fraction of the originally anticipated investment, while avoiding the additional complexity, energy consumption and maintenance requirements associated with a refrigerated cooling system.

THE CHALLENGE

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After baking, the cereal product was distributed into trays and loaded onto mobile racks for cooling before continuing to the next production stage.

The existing cooling process relied on general ambient-air fans. Although air was being moved around the racks, cooling performance was inconsistent and longer than desired.

Several issues were identified:

• Cooling time was longer than required

• Airflow was not properly directed through the rack

• Some trays received significantly more airflow than others

• Product temperature varied depending on tray and rack position

• A portion of the fan airflow bypassed the product entirely

• Existing fan power was not being used efficiently

• Cooling performance had not been quantified through temperature and airflow measurements

• The proposed refrigerated cooling system represented approximately $55,000 in capital investment

• Refrigeration would also introduce additional energy use, maintenance requirements and system complexity

The objective was to determine whether the required cooling performance could be achieved through a better-engineered airflow system before committing to major capital expenditure.

ENGINEERING SOLUTIONS

01 | EXISTING PROCESS EVALUATION

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Understanding the Real Cooling Limitation
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The study included:

• Product condition after baking

• Product loading and distribution on trays

• Tray dimensions and spacing

• Rack configuration

• Existing cooling cycle

• Ambient temperature

• Product temperature throughout cooling

• Existing fan locations and capacity

• Airflow paths around and through the racks

• Temperature variation between tray positions

This established a measurable baseline and helped identify where cooling performance was being lost.

The evaluation showed that simply adding colder air would not necessarily solve the underlying issue. The available airflow first needed to be properly distributed across the product.

02 | PRODUCT & TEMPERATURE ANALYSIS

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Determining the Actual Cooling Requirement

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Product temperatures were measured throughout the cooling cycle to understand how heat was being removed and how cooling performance varied across the rack.

The analysis considered:

• Initial product temperature

• Cooling rate over time

• Target product temperature

• Temperature variation between trays

• Temperature variation between upper, middle and lower rack positions

• Effect of ambient conditions

• Required cooling time for the next production stage

This allowed the cooling requirement to be defined using actual process data rather than assumptions.

03 | AIRFLOW STUDY

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Finding Where Fan Capacity Was Being Lost

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The existing fan arrangement was studied to determine how air actually moved around and through the loaded racks.

The evaluation included:

• Air volume

• Air velocity

• Fan static-pressure capability

• Rack resistance

• Tray spacing

• Product exposure to airflow

• Air bypass around the rack

• Recirculation areas

• Low-flow and dead zones

• Differences in airflow between tray levels

The study demonstrated that air distribution was the primary restriction to cooling performance.

A significant portion of the available fan capacity was not contributing effectively to product cooling because the airflow was not being directed through each tray level.

04 | CUSTOM AIR DISTRIBUTION SYSTEM DESIGN

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Turning the Analysis into a Physical Solution

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Based on the airflow and temperature study, ExtremeTech designed a new fan distribution system specifically for the rack and tray configuration.

The solution focused on delivering useful airflow directly toward the product instead of simply increasing general air movement in the area.

The design included:

• Selection of appropriate fan capacity

• Optimized fan positioning

• Directional air flaps

• Air-distribution baffles

• Flow-guiding panels

• Features to reduce airflow bypass

• Improved distribution between tray levels

• Adjustable airflow elements for balancing

• Mechanical support and mounting structures

The design created a controlled airflow path that directed air toward each tray across the rack, significantly improving the use of the available fan power.

05 | FABRICATION & INSTALLATION

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Delivering the Engineered Solution

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ExtremeTech did not stop at the engineering study.

The project progressed from analysis and design through fabrication, installation and implementation of the physical cooling upgrade.

The delivered system included:

• Fan assemblies

• Fan mounting structures

• Directional flaps

• Air-distribution baffles

• Air-guiding panels

• Mechanical supports

• Flow-directing components

• On-site positioning and adjustment

• Integration with the existing production process

This converted the engineering concept into a practical production solution without requiring major changes to the existing plant layout.

06 | AIRFLOW BALANCING & COMMISSIONING

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Directing Air Properly Across Every Tray

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Following installation, the airflow system was commissioned and adjusted under real operating conditions.

The work included:

• Fan positioning adjustments

• Air-direction verification

• Flap and baffle adjustment

• Reduction of airflow bypass

• Elimination of low-flow areas

• Improved airflow across upper, middle and lower trays

• Balancing of airflow between rack positions

• Verification that air passed through the product zone rather than around it

This commissioning stage ensured that the installed fan capacity was converted into effective and uniform product cooling.

07 | TESTING & PROCESS VALIDATION

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Confirming the Result Under Production Conditions

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The completed system was tested during normal production to verify that the airflow upgrade achieved the required cooling performance.

Validation included:

• Product temperature monitoring

• Cooling-time measurement

• Comparison between tray positions

• Final product temperature

• Cooling uniformity

• Airflow coverage

• Repeatability between batches

• Product-quality observation

Adjustments were made until the system produced stable and repeatable performance.

The final configuration successfully delivered the required cooling result using optimized ambient airflow rather than mechanical refrigeration.