Regional Dairy Reduces Maintenance Costs by 75% and Energy Use by 20% with Absolute Zero System Upgrade
- Overview
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Customer
Maple Creek Dairy, a regional producer of artisanal cheese and dairy products in Wisconsin, USA.
The Challenge
Maple Creek Dairy’s aging cold storage refrigeration system was becoming a financial drain. The old piston compressors were inefficient, noisy, and required constant, costly maintenance. A system failure during a summer heatwave had resulted in the loss of thousands of dollars worth of product. They needed a modern, reliable, and energy-efficient solution that would protect their inventory and reduce their soaring operational expenses.
The Solution
Absolute Zero proposed a complete system overhaul, replacing the patchwork of old equipment with an integrated solution:
•Two AZ-CU 50kW Condensing Units: These plug-and-play units, featuring multi-compressor parallel technology, provided the redundancy and efficiency the facility needed.
•Six AZ-SC 15kW Scroll Compressors: The heart of the new system. These ultra-quiet, high-efficiency compressors replaced the noisy, maintenance-heavy piston units.
•AZ-EV Series Electronic Expansion Valves: Installed on each evaporator to ensure precise temperature control and optimize system efficiency.
The Results
The upgrade transformed Maple Creek Dairy’s operations, delivering significant financial and operational benefits:
•75% Reduction in Maintenance Costs: The move to our 5-year maintenance-free scroll compressors and reliable condensing units virtually eliminated emergency repair calls, reducing their annual maintenance budget by 75%.
•20% Reduction in Energy Consumption: The combination of high-efficiency compressors and precision control from the electronic expansion valves led to a 20% decrease in the refrigeration system’s electricity usage.
•Zero Product Loss: In the 18 months since the installation, they have had zero product loss due to equipment failure, even through two hot summers.
•Improved Work Environment: The dramatic reduction in noise from the new scroll compressors significantly improved the working conditions for employees near the machine room.
“The difference is night and day. Our old system was a constant headache. The new Absolute Zero system is quiet, efficient, and I haven’t had to call a repairman once. I can finally focus on making cheese instead of worrying about my refrigeration. The savings on our electricity and maintenance bills are just the icing on the cake.”— John Miller, Owner, Maple Creek Dairy
