forum - Chillmatch.com

FORUM 1
THE TRADE JOURNAL FOR REFRIGERATION TECHNOLOGY 2006
www.kueba.com
Visit Küba at iKK 2006
in Nuremberg from 18
to 20 october 2006, Hall
4, Stand 508
Next ecoNomy liNe Cool play in the Allianz Arena
Hotel & ReStAURANt iNDUStRy Cooling à la carte | meAt RetAil Healthy treats | RefRigeRANt co 2
Best energy balance | AiR DiStRiBUtioN Customised cooling | KüBA iNSiDe Fresh breeze for wind power

02 | eDitoRiAl | coNteNtS | iNteRVieW | iNteRNAl | AcceSSoRieS | iNSiDe | RePoRt | eVeNtS | PRActice | SeRVice
coNteNtS
03 | iNteRVieW
A perfect complement. interview with new Küba sales
manager Don van Wezel.
04 | iNteRNAl
Simple, reliable, fresh. An overview of the new green
economy line and its features.
06 | RePoRt
cool play. Küba and its green economy line in the refrigeration
line-up for the new Allianz Arena.
10 | cooling à la carte. the right cooling solution for the
Hotel Pfaffinger Hof.
12 | meat that’s a treat. Healthy enjoyment of fine delicacies
from Upper Austria’s ideally cooled meat market
fleischhauerei Schuster.
20 | Best energy balance. the environmentally-friendly refrigerant
co 2 in Switzerland’s Aligro bulk supermarkets.
15 | eVeNtS
meet us at the iKK. All about the iKK and the new
chillventa, which will open its doors in 2008.
16 | iNSiDe
A fresh breeze for wind power. top Küba cooling for
wind turbine generators.
18 | AcceSSoRieS
Uniformly well cooled. the advantages of thermotex
textile hoses at a glance.
23 | fReQUeNtly ASKeD QUeStioNS
the new elektrog. What refrigeration engineers need to
know.
StANDARDS
02 | eDitoRiAl / coNteNtS
02 | imPRiNt
eDitoRiAl
DeAR ReADeR,
Europe’s prospects for the next six months may seem sobering:
higher taxes, a strong Euro, high oil prices, expensive raw materials
like copper or aluminium and a sluggish world economy.
Nevertheless, we have no reason to be pessimistic.
With an intelligent and bold product strategy we intend to master
the downswing without side effects. For instance, with our new
green economy line, and with our blue Classic Line we have
tailored our product portfolio to precisely meet the needs of our
customers. Ubiquitous cost pressure does not have to lead to a
reduction in quality.
As an experienced manufacturer of high-quality refrigeration
components, Küba believes that the optimal cost/benefit ratio of
our products is the best basis for a mutually successful partnership
with planners, engineering companies and operators. At a
time when other companies are tempted to cut costs by reducing
quality, our reaction is is to do just the opposite: We have an
obligation to our partners in the market to strictly maintain and
enhance our high quality standards in production, the materials
used and in the way we do business. In this way, we aim to
strengthen the bonds of our common success – quality unites
and creates new opportunities.
May you enjoy this issue,
Don van Wezel
imPRiNt
FORUM The trade Journal for Refrigeration Technology
PUBLISHER: Küba Kältetechnik GmbH, Oberdiller Straße 23, D-82065 Baierbrunn,
Tel.: +49/(0)89/74473-264, Fax: +49/(0)89/74473-107 MANAGING EDITOR: Michael
Münch (Küba Kältetechnik) CONTRIBUTORS TO THIS EDITION: Don van Wezel,
Josef Irl, Eng. Peter Strauß, Oliver Memminger, Kai Krebs, Marcus Höpfl, Peter Rudolf
Wohlmuth, Dr. Gabriele Lüke, Petra Sippel EDITING, LAYOUT & PRODUCTION:
imprime – Dr. Lüke, Mai & Partner – Journalists & graphic designers, Perchtinger Str.
8–10, 81379 Munich, Tel.: +49/(0)89/747344-73 and -74 PRINTING & SHIPPING: artconcept
Werbeagentur GmbH, Martinsried/Munich
Reproduction only by written permission from Küba Kältetechnik GmbH. Copyright reserved. We
do not accept responsibility for unsolicited manuscripts, pictures and files.
SeRVice | PRActice | eVeNtS | RePoRt | iNSiDe | AcceSSoRieS | iNteRNAl | iNteRVieW | coNteNtS | eDitoRiAl | 03
Mr. van Wezel, the new Küba economy line has been on the
market since January 2006. How are sales?
We are very pleased about its successful start. We receive new
enquiries on a daily basis from potential customers in Germany
and abroad.
This shows that Küba understands the needs of the market.
Why is the new line so appropriate for the market?
The new economy line is an efficient solution for standardised
cooling tasks in the retail and service sectors – in other words,
for non-sensitive refrigerated goods that just need a constant
temperature. In this regard, the green economy line also perfectly
complements our blue Classic Line, which is designed
for complex or custom refrigeration in the manufacturing and
processing industries.
Does the standardised refrigeration you mentioned represent a
growing market segment?
The service and retail sectors need fast and intelligent solutions
for standard cooling tasks. Supermarkets, grocery stores, filling
stations, restaurants, catering services, or kiosks everywhere
are confronted with the same challenge: They have to refrigerate
packaged products, (products that leave the sales and work
areas in the same condition in which they were brought in), for a
relatively short period. During this period the products must be
simply reliably fresh – nothing more and nothing less.
Simple, reliable, fresh – that is also the motto for the new economy
line.
Exactly. Simple to install, absolutely reliable to operate: Thus,
the cooled goods always stay fresh. And this means that our
customers get a solution that perfectly meets their needs.
A perfect complement
Don van Wezel has been managing sales at Küba since January
1st, 2006. He explains to foRUm what sets the economy line Air
cooler product line apart.
This must make them happy.…
That’s not all. We can deliver the units with short lead times.
They are quickly and easily installed, and cleaning is quite simple
– which naturally is an extremely important factor in the food
industry. Of course the new unit line has also been priced attractively.
And for complex cooling tasks there is the Classic Line.
The Classic Line always comes into play whenever more than
just temperature is involved. This is the case, for example, when
factors such as long-term storage, assurance of maturation
processes, humidity, precise air distribution, hygiene, or corrosion
protection in acidic environments play a crucial role. And
this increases the complexity of the units accordingly.
Is that the essential distinction to the economy line?
Exactly. The blue and the green worlds are completely complementary.
They only differ in their respective areas of implementation
and thus their complexity. This, of course, means that the
new economy line delivers the proven Küba quality: high cooling
capacity through the CAL® distributor effect, long service
life, high level of installation safety, as well as the hygienic powder
coating. From a technical perspective, what makes the new
economy line an autonomous unit line is its equipment: This
line satisfies the standardised requirements of the application
scenarios. The buzzword here is “built to application”.
This concept raises the bar for the competition. Currently, none
of them has such as offering.
True. The new economy line was definitely the right decision for
Küba. Now we can serve all market segments comprehensively,
01/2006 FORUM

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Simple, reliable, fresh
Küba has successfully positioned itself in line with market demands with its new green economy line: From
standardised to complex cooling tasks – Küba offers the right solution for any application.
WitH itS NeW ecoNomy liNe Küba‘s developers have succeeded
with an innovative, market-driven extension to the product
line: The economy line’s state-of-the-art Air Coolers offer a
solution that is designed especially for standardised cooling
tasks in the retail and service industries. “With this new addition
Küba now has a seamless portfolio of both complex Air Coolers,
as well as standardised Air Coolers,” explains managing direc-
junior Df
➡ Space-saving:
Horizontal drain enabling a height reduction to 180 mm, including
the 90° elbow
➡ Best air guidance:
Integrated air baffle plate projects the air along the cell ceiling
and thus far into the room
➡ for extreme applications:
Installation of an additional heater is possible, for example, for
use in deep-freeze rooms subject to frequent door opening
➡ Simple installation:
The unit can be easily screwed to the cell ceiling; removable
fan plate
tor Thies Hachfeld. Standard cooling tasks are handled by the
green economy line, whereas the proven multi-variant Classic
Line is designed for complex or custom refrigeration installations,
particularly in the processing and manufacturing industries.
Such a differentiation makes sense: “Non-sensitive” packaged
goods that leave the store in the same state in which they
were delivered and which usually are stored for short periods
compact Df
➡ Simple installation:
Hinged fan plate, removable side piece
➡ Space-saving:
Drain vertical, height including drain 315 mm
➡ Narrow width:
Compact design, only 872/972 mm wide
➡ Best air guidance:
Integrated air baffle plate projects the air along the cell ceiling
and thus far into the room
at a constant temperature, do not need complex Air Coolers. In
this case temperature is the only significant refrigeration quality
parameter. The goods must be simply and reliably fresh. And
this is precisely what the new product line offers: The economy
line is simple to install and clean, absolutely reliable to operate
and it always keeps the refrigerated goods fresh. In other words,
it is a market-oriented solution in proven Küba quality. The new
product line has been priced attractively. In addition the units
are always available with short lead-times.
What makes these units into an autonomous product line from
the technical perspective is primarily their equipment: This line
perfectly satisfies the standardised requirements – “built to application”.
The new line comprises differentiates four product
series: junior DF, compact DF, market plus SP and comfort DP.
➡ expanded capacity range:
Now up to 52 kW
➡ incremental capacity steps:
now with fan diameter 500 mm
➡ increased air throw:
Küba Air Jet as accessory
➡ Quick cleaning:
Hinged drain tray as accessory
market plus SP comfort DP
www.next-economy-line.de
Each series has several design variants ranging from 0.5 and
50 kW.
By contrast, the Classic Line is designed to handle complex
cooling tasks for the manufacturing and processing industries,
i.e. wherever more than just the temperature of cooled goods is
essential. Here, factors such as long-term storage, assurance
of maturation processes, humidity, air distribution precision, hygiene,
or corrosion protection for acidic environments, play a
crucial role, for example. Managing director Thies Hachfeld is
pleased: “This differentiation makes it clear why the new economy
line is the right decision for Küba: Now we can serve all market
segments comprehensively, in line with demand and with
the highest level of quality.”
➡ expanded capacity range:
Now up to 28 kW
➡ Space-saving:
Height 303 mm
➡ Best air guidance:
Integrated air baffle plate, low air speed (to 0.8 m/s projects the air
along the ceiling of the cell and therefore far into the room
➡ Virtually no draught:
Low air speed in the cooling room through integrated air baffle
plate, low-noise version integrated (standard with two-step
fans), extremely quiet version in the third speed “S” with accessory
(condenser)
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cool Play
www.next-economy-line.de
The architecture and colourful lighting of
new Allianz Arena in Munich are captivating
to be sure. But that’s not all. It also
has some real refrigeration engineering
highlights to offer.
footBAll mAKeS PeoPle HUNgRy and
thirsty. Particularly the fans. Sharing the thrill
also takes energy. The operators of the new Allianz
Arena in Munich were justified in making
sure that fans were well cared for. The stadium
can accommodate up to 70,000 people, and
they want to eat and drink. They can get bratwurst,
pizza, or French fries for snacks. In two
Fan-Centres, Munich breweries, Hacker Pschorr
and Paulaner, dispense their respective brands
of beer to the fans. Arena à la Carte is a family
restaurant whose bar and bistro offer a menu
to fit the tastes of parents, children, VIPs and
sponsors. During the off-season high-quality
fare must also be ensured so that the stadium
can be used as a location for events, conferences
or symposia. Given these diverse catering
scenarios ranging from mass to exclusive,
intelligent and efficient solutions were required
particularly from refrigeration engineers. The
variety of cooled goods is every bit as varied
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1
as the individual tastes of the fans. The refrigeration technology
had to meet the widest variety of requirements imposed by the
goods that will be cooled. The number of people to be served
was also a factor that could not be underestimated:
• 2,200 sponsors,
• 2,600 business seat owners,
• 1,500 VIPs,
• 1,300 visitors each at the two Fan-Treffs and
• the queues that can be expected in front of the 28 kiosks.
All these people not only want a wide variety of enough food
and beverages from the two main kitchens; they also expect all
products to be processed with perfect quality. By the way, most
of the products offered come from the region.
Responsible for the overall catering concept was Arno Stuckert
of Augsburg, a respected specialist planner for the food services
industry. Muhr GmbH from Viechtach in Lower Bavaria and
Kühlanlagenbau Süd-Ost GmbH from Dresden both oversaw
the operative refrigeration engineering implementation. Muhr
was responsible for the cooling systems for the two large kitchens,
while Kühlanlagenbau Süd-Ost GmbH equipped the kiosks.
Installation started in November 2004. In this process the
refrigeration systems were installed first, followed by the insulation
installations. As the prerequisite for the system’s function,
a chiller system with condensing units was installed on each of
the seven levels of the stadium. All of the condensers required
2
for food service applications were connected to this system.
The water feed temperature is +8 °C, the return temperature is
+40 °C, maximum. Relative to the water-cooled condensers that
were used, the operators placed a primary value on extremely
quiet operation; in this case the value of 35 dBA was not to be
exceeded. Levels 3 and 4 are a good example of the specific
refrigeration requirements:
On level 3 in the family restaurant area
• a cooling room for beverages (36 m 3 ),
• a cooling room for dairy products (15 m 3 ),
• a cooling room for vegetables (20 m 3 ),
• a cooling room for meat (20 m 3 ),
• eight refrigeration tables, refrigerated well buffets and walk-in
coolers needed to be supplied.
On level 4 in the main kitchen area
• a cooling room for beverages (52 m 3 ),
• a cooling room for dairy products (31 m 3 ),
• a cooling room for vegetables (46 m 3 ),
• a cooling room for meat (46 m 3 ),
• a cooling room for finished goods 1 (42 m 3 ),
• a cooling room for finished goods 2 (42 m 3 ),
• a cooling room for tableware (31 m 3 ),
• a cooling room for ice cubes (22.5 m 3 ),
• cooling for the prep room (129.5 m 3 ) as well as
• cooling for the equipment room (33 m 3 )
were on the agenda.
Küba Kältetechnik supplied the fan Air Coolers for implementation
of the plan. The market plus SP series from the new green
economy line and some SG evaporators with increased blow
range, directed air flow and higher compression were also used.
Thus, Küba units are used in all areas: In the large-scale catering
kitchens, in the prep rooms (here some units featured textile
hose adapters), in the open cooling rooms, in the deep-freeze
rooms, and in the kiosk areas. In line with the new dual division
of the Küba world; the Küba Air Coolers offer solutions for both
complex cooling tasks, as well as standardised cooling tasks
– such as those required in the kiosk area.
Nevertheless, the refrigeration engineering challenge posed by
the Allianz Arena with the number and variety of requirements
associated with the different cooling tasks. The installation itself
involved some special features. For example for stadium levels
3 and 4 it was possible to connect all entities requiring refrigeration
on these two levels to the cold water plumbing via two multicompressor
cooling systems; in other words it was possible
to create an integrated solution. However such a construct was
not possible for the other levels. Here 19 individual water-cooled
condenser units were installed and connected individually to the
cold water plumbing. These water-cooled condenser units were
directly installed above the cooling rooms – between the cooling
room ceiling and the rough ceiling. In addition all cooling ag-
moRe iNfo
FORUM 01/2006 01/2006 FORUM
3
5
4
6
www.next-economy-line.de
1 View of the stadium:
A dream for every football
fan – and refrigeration
engineer
2 Josef Köppel, supervising
fitter for muhr gmbH
– final mounting of an SP
evaporator
3 Universal market plus
flexibility: in photo
number 3 the frozen
goods are kept in the
deep freezing room at -35
°c, packaged of course,
and …
4 … in photo 4 vegetables
are cooled „simple,
reliable, fresh“ in open
containers.
5 the junior Df fits into
small, low-ceiling cooling
cells with a big effect:
here in one of the kiosk
cooling cells
6 it makes queuing worthwhile:
Beverages and
snacks await hungry and
thirsty fans at
gregates were fitted with a data interface. Thus, fault messages
can be detected quickly and the faults can be resolved. The
following areas are among those supplied individually:
• Beverage cooling room level 3, sector 1 (97 m 3 room volume),
• Wet waste cooling room level 0, sector 4 (43 m 3 ),
• Deep freeze room level 0, sector 4 (70 m 3 ),
• Beverage cooling room level 4, sector 3 (76 m 3 ),
• Food cooling room level 5, sector 1 (49 m 3 ),
• Shock cooler with 12.5 kW cooling capacity.
Given this sophisticated planning and installation nothing can
go wrong in the competition for the German and International
championships – as the World Cup has clearly shown. Cold
beer, delicious bratwurst and a lot of goals – the football fan has
every reason to be happy.
there are 62 Air coolers from the blue and green Küba world in
the Allianz Arena. together they represent total cooling capacity of
158.15 kW. A list of aggregates, their respective areas of implementation
and their cooling capacity is available at http://www.kueba.
com/kueba/deutsch/nbsp/menu/what_146_s_new/aktuelles/forum/
index.html

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FORUM 01/2006
cooling à la carte
An integrated compressor solution and the junior DF ensure optimal and energysaving
refrigeration at the Hotel Pfaffinger Hof.
Sparkling clean and brilliant – like this kitchen in the Hotel Pfaffinger Hof – is what guests expect of a good kitchen in the hospitality industry.
Adjacent is a view of the deep freeze cell: Here, vegetables and fruit deep frozen are kept fresh for processing at a room temperature of –20
°c. Here, the junior Df from the green Küba economy line makes sure that temperatures are kept constant (photo far right).
“gooD RefRigeRAtioN iS an absolute necessity in the hotel
and restaurant business”, says Alois Bichler, owner of the
Pfaffinger Hof hotel. It should come as no surprise then that he
had a very clear idea about the quality of the cooling systems
that he needed for his new hotel. So, for refrigeration engineer
Josef Irl, managing director of Irl Kältetechnik GmbH & Co. KG
in the Bavarian town of Edling, there was only one solution. He
ordered from Küba. “Only Küba supplies the high-quality demanded
for a really good cooling system,” is Irl‘s conviction.
The Pfaffinger Hof is a brand new hotel that was built in 2003 in
Pfaf-fing am Inn, a town located located on the Inn river in the
foothills of the Alps. “We combine traditional Bavarian atmosphere
with the comfort of a modern hotel”, is how hostess Luise
Bichler describes her hotel’s philosophy. Regardless of whether
guests are planning a tranquil private holiday, a relaxing business
trip, or a family celebration – the Pfaffinger Hof always
offers the right ambiance. First and foremost, however, Luise
Bichler wants to spoil her guests with hearty regional cuisine.
The kitchen‘s offerings range from cream aspic to roast venison.
It is thus logical that refrigeration was of central significance for
the Bichlers as they planned the new building.
Altogether, 5 cooling rooms needed to be equipped: a deep
freeze room, separate cooling cells for meat, beverages, and
vegetables, and a kitchen cooling cell. Two special requirements
were important for the design of overall solution. Firstly,
Alois Bichler placed high priority on an energy-saving system.
Secondly, because the cooling cells are quite small, high-quality
units with minimum space requirements were needed. These
were the interior dimensions in the specification (L x W x H).
Deep freeze cell: 2,100 mm x 1,000 mm x 2,480 mm
meat cooling cell: 2,140 mm x 1,000 mm x 2,380 mm
Kitchen cooling cell: 2,140 mm x 1,700 mm x 2,380 mm
Vegetable cooling cell: 2,140 mm x 1,000 mm x 2,380 mm
Beverage cooling cell: 3,880 mm x 2,680 mm x 2,080 mm
The solution, which was installed between January and October
2003, was very elegant. On the compressor side, Pfaffinger Hof
opted for an integrated solution rather than one consisting of
different individual systems. The specific advantages of this integrated
system are explained at the end of the article. Küba evaporators
were used to equip the cooling cells. Due to their limited
space, Irl selected the slender junior DF from the new green
Küba economy line. The cooling cells were not completely lined
during installation. Instead, individual cooling cell panels were
cut to size and mounted together. The condenser was installed
in the attic storey.
Now the necessary temperatures can be achieved effortlessly.
In the deep freeze cell a temperature of –20 °C is ensured; the
meat cooling cell is 0 to +2 °C, guaranteed; the standard temperature
in the kitchen cooling cell is +3 °C; vegetables are refrigerated
at +5 °C; and beverages are refrigerated at +6 to +8
°C. Since the Küba units are easy to operate, defrosting and
cleaning are also easy: Twice a day the cooling cells are automatically
defrosted at a final defrosting temperature of +8 to
+10 °C. The cells are cleaned as needed.
Dixell regulators are used to control cooling cell temperature. A
frequency converter is used to regulate the integrated system
from the compressor side.
Moreover, the integrated solution cited proved to be the superior
solution as far as saving energy was concerned. “If we had used
individual systems then we would have had to install a separate
aerating and venting system. That would have meant unnecessarily
higher installation expenses and in addition it would have
driven up the energy costs”, explains refrigeration engineer Irl.
The integrated system saves the customer, as desired, energy
and thus cash in hand. The system consumes between 20 and
35 percent less energy than would have been consumed with
implementation of individual systems.
The integrated system, with heat recovery in combination with
Küba evaporators and the Küba condenser in the attic storey,
controlled by frequency converters and Dixell regulators, thus
enabled a customised, high-performance and in terms of energy,
a highly economical system. Alois Bichler got precisely
the solution that he desired: “The system functions well, to this
point there have been no problems worth mentioning. I am very
pleased”.
irl Kältetechnik gmbH & co. Kg
the company, headquartered in the Bavarian town of edling, was
founded in 1966 and is now managed by Josef irl in the second generation.
the company specialises in refrigeration, air-conditioning
and heat pump technology for commercial and industrial applications.
their extensive offering consists of sales, planning, configuration,
installation of new and used cooling systems, as well as heat
pump systems, maintenance, customer service, and on-call duty,
recycling and conversion of old cooling systems.
more information at: www.irl-kaeltetechnik.de
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FORUM 01/2006
Keeping meat a treat
In order to offer its customers top quality, Fleischhauerei Schuster, a specialty meat market in
Upper Austrian Ostermiething purchased a state-of-the-art cooling system.
toDAy’S Pig is tomorrow’s ham is a saying that also applies
in Ostermiething in Upper Austria. This is where the specialty
meat market Fleischhauerei Schuster is headquartered. The
family-owned company is known for fine hams and many other
meat delicacies. In addition the firm offers party service, canteen
management, wedding and event catering in all variations: from
cold cuts, to finger food, to buffets, and from small gatherings
to major functions. And to ensure that meat, ham and sausage
arrive on the table in top quality, the Schuster family naturally
optimises its refrigeration installations on a regular basis.
The latest round of modernisation began in April 2003, when
the Schusters had decided to build a new large meat processing
facility with adjoining sales area and residential quarters.
New construction had become necessary because the existing
facilities were bursting at the seams and more space was urgently
needed. In terms of the refrigeration technology this was
an opportunity to make a major step forward. The previous solution,
which consisted primarily of individual aggregates, was
replaced with a sophisticated integrated solution with supplemental
individual systems.
Concept design and system implementation were handled by
Strauß Kälte-Klimatechnik G.m.b.H. in Salzburg. As a longstanding
business partner of the Schuster family Strauß was a
natural choice for this job. The firm was able to individually and
optimally satisfy the needs of the customer.
The new installation, which represents the state of the art in
terms of energy and hygiene, has been in operation for the fa-
tecHNology: KüBA comPoNeNtS At A glANce
the home of specialities: Butcher shop, party service, canteen management
and refreshments, all in one.
cility since March 2004. The cooling system had to satisfy the
a number of demanding specifications. It had to offer optimal
energy efficiency and be configurable for different temperature
ranges. It also had to be suitable for different application scenarios,
which meant that it must provide cooling as well as airconditioning
control. This was the prerequisite for ensuring optimal
conditions in each of the different areas. Temperature and
humidity can be precisely matched to the needs of the rooms.
Air speeds can also be adjusted. For instance, in rooms where
Application / cooling room Quantity Air cooler type Room temperature in °c Dt1 Rel. humidity
Ground floor
Cutting 1 DPA 044-N +10 8
Production 1 DPA 044-N +10 8
Meat cooling room 1 SGAE 92 0 7 90– 95
Curing room 1 SGAE 81 +2 7
Acclimatised room 1 SGA 61 +10 10 60–70
Deep-freeze room 1 SGBE 91 – 22 7
Consignment cooling room 5 KVB 2928 0 8 90
Packaging 1 DPA 044-N +10 8
Loading 1 DPA 042-N +10 8
Hallway 1 DPA 042-N +10 8
Waste 1 SPA 042C +4 8
KR kitchen 1 SGAE 81 0 7 90
Sales cooling room 1 KVB 2923 0 8 90
Basement
Cooling room 1 SGAE 81 +4 7 90
Deep-freeze room 1 SGBE 82 – 22 7
www.next-economy-line.de
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FORUM 01/2006
Photo left: Refrigeration competence prior to regulating the system: engineer Peter Strauß (l.) and franz Schuster. Photo right: comfortable
working area: under the DPA044 ceiling Air cooler at maximum 0.8 m/s air speed in the cutting and processing area.
employees are working all day, the air speeds must be kept as
low as possible to avoid draughts.
thus, the cooling system was organised as follows:
• compressor unit for cooling rooms
• compressor unit for cutting rooms and work rooms
• compressor unit for small cooling units in the sales area
• individual systems for deep freeze rooms to
optimise energy consumption and ensure operational reliability.
mode of operation: the work process of a butcher‘s shop
starts in the cutting room. in an area of approximately 75 m²
meat products are precisely cut under a four-motor comfort
DP ceiling Air cooler from the new green Küba economy
Strauß Kälte-Klimatechnik g.m.b.H.
Strauß Kälte-Klimatechnik g.m.b.H. in Salzburg-tahlgau can look
back on over 40 years of refrigeration and air-conditioning engineering
experience. Refrigeration and air-conditioning engineering for
the food and beverage sector, food retail, supermarket, fresh produce
warehouses, meat processing plants, as well as building climate
control, are all part of the company‘s range of services. in these
segments the company, which is also one of the five owners of Kältering
Austria (a wholesaler serving food and beverage companies),
is one of the strongest family-owned companies in Austria. engineer
Rudolf Strauß, responsible for technology, and engineer Peter
Strauß, responsible for sales, are driving the company’s expansion
course. An important phase started for Strauß in 1998: the firm moved
into its new building. the facility is approximately 5,500 m 2 and
includes 1,300 m 2 of warehouse, production, office space.
line. thanks to the low air speed of maximum 0.8 m/s, work
under these Air coolers is quite pleasant.
After fine cutting, the meat then goes to further processing
and then onto smoking in the smoker systems, or cooking in
the multi-cart cooking systems. the next step is to cure (preserve)
the sausage and meat products. the curing chamber
is maintained at a constant +2 °c by an electrically defrosted
SgA81. connected to the curing chamber are a consignment
cooling room (pre-picking cooling room) and a meat
cooling room that are both equipped with static Air coolers.
A packaging and loading area is next to the consignment
cooling room. this is where a four-motor and a two-motor
comfort DP ceiling Air cooler perform their labour. All DP
units are equipped with speed switches to avoid draughts.
“Our efforts were directed towards installing an economic and
also a technically sophisticated, standard solution with multiple
systems,” emphasises Rudolf Strauß, who designed the system.
“Our principle is: Intelligent and synergetic solutions for
the client‘s specific requirements.” Strauß opted for Küba units
due to the broad product line. “Thus, we were able to avoid mixing
different makes.” The customer, Fleischhauerei Schuster, is
very pleased with the system, which has been working perfectly
since operation began. And the end customers enjoy the fine
products.
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Welcome! We will be presenting the new green economy line and two units from the classic line together with our group partners on our
iKK trade show booth. Stop by and talk to us. We look forward to seeing you (Hall 4, Stand 508)!
meet us at the iKK
This year in Nuremberg the IKK will open its gates for the last time. It will be reborn in 2008 as
Chillventa. Küba and the new economy line will be there, in 2006 and in 2008.
WitHiN A VeRy SHoRt time the new green economy line has
become an established concept among cooling experts. After a
successful roadshow in the first quarter of this year and an inhouse
show at Küba’s headquarters in Baierbrunn, the four new
product lines will now be introduced to a larger public at IKK in
Nuremberg. The economy line products will be supplemented
in Nuremberg by two multi-variant units from the blue Classic
Line, which are designed for the long-term storage of sensitive
products in open containers. Dear reader, we invite you to visit
our stand from the 18th to the 20th of October and talk to us.
The history of this show will come to an end with this year’s IKK.
In July 2006, 26 companies and 5 organisations in the air conditioning
and refrigeration industry, including Küba Kältetechnik
GmbH, founded the Chillventa exhibitor group. This group will
form the basis of a new trade show, the Chillventa. It will open its
gates in October 2008 and will take the place of the IKK.
Why a new trade show? This development came about after discussions
concerning the future of our industry trade fair with the
German Refrigeration & Air-Conditioning Association (Verband
Deutscher Kälte-Klima-Fachbetriebe (VDKF)), failed conclusively
mid-year – despite the efforts on all sides. The VDKF wanted to
continue holding the IKK annually in spite of the disappointment
experienced at the Hanover Fair in 2005, where 50 percent fewer
visitors attended. In addition the idea was to combine the IKK in
odd number years with the large ISH/Aircontec trade fair held in
Frankfurt, which is carried primarily by the heating and sanitation
industries and their industry associations. This would have compromised
the conceptual clarity of the IKK. Moreover the VKDF
had planned to give up the successful and internationally esteemed
trade fair venue of Nuremberg.
Many exhibitors did not agree with these proposals. Thus, the
exhibitor group, Chillventa Nuremberg, was formed, which in
the meantime has been extended by the addition of several major
companies and which also has been able to win the German
Federal Guild, Association of the Cooling and Refrigeration
Trade (Bundesinnungsverband des Deutschen Kälteanlagenbauerhandwerks
(BIV). The BIV represents 19 state guilds and a
total of 1,100 refrigeration and air-conditioning firms. Moreover,
10 Italian industry companies have declared their support for
the new Chillventa.
NürnbergMesse will organise the new trade fair. It will invest considerably
in Chillventa. Among other things NürnbergMesse has
agreed to reduce exhibitor rental rates by more than 10 percent,
double the advertising budget and to appropriately compensate
the services of associations, organisations and institutions. With
this modernised trade fair concept the Chillventa will continue
the successful history of the IKK: under a new name at an esteemed
trade fair venue.
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FORUM 01/2006
gooD NeWS foR tHe eNViRoNmeNt – AND tHe ecoNomy.
Sustainable decentralised power generation is developing
into a pronounced growth market. Soon wind energy will
become the most significant source of regenerative energy and
will replace hydropower in this category.
Thus, future perspectives for the Nordex Group, one of the
world‘s largest suppliers of wind turbines, could not be better.
The same applies for its strategic partner, Winergy AG from
Voerde on the lower Rhine. Winergy, a long-standing Küba customer
is the leading provider of gear units and generators for
wind turbines with locations in Voerde and Ruhstorf in Bavaria.
The Voerde site produces the gear units, while Ruhstorf is responsible
for the generators.
Together with the Nordex Group, Winergy have implemented
an outstanding reference project, in which Küba is also a participant:
the Windpark Ketzin, currently the largest wind farm in
Germany. Ketzin is located approximately 20 kilometres north
A fresh breeze for wind
power
To optimally cool the wind turbine’s generators, Winergy AG relies on heat
exchangers with maximised surface area.
The contribution made by refrigeration technology: A wind turbine
has approximately 18 different components. For example,
gear units, clutches or frequency converters. Moreover, there
is also a generator with a capacity of up to 2,500 kW that is
part of such a turbine. The generator must be cooled with water.
Since a large share of the components are delivered by Winergy
AG, Küba‘s participation in this exciting project was a natural
choice. A heat exchanger with the largest possible surface area,
this means the greatest possible heat exchanging capacity was
required to cool the generator. At the same time, this heat ex-
Winergy Ag
Winergy Ag (headquartered in Voerde) is the leading provider of gear
units and generators for wind turbines. in recent years the company
has extended its market share to more than 40 percent. in the wind
turbine segment with more than one megawatt capacity, (the so-called
megawatt class), Winergy even has a market share of more than
50 percent. of the 49,000 wind turbines installed worldwide, 24,000
of them are equipped with Winergy gear units. this corresponds to a
market share of more than 45 percent. in addition Winergy is among
the leading suppliers of generators for wind turbines with a world
market share of approximately 16 percent.
of Potsdam in an area on the Nauner plateau that is zoned for
wind power generation. It was built in early 2005 by the Nordex-
Winergy team for e.disnatur, a subsidiary of Fürstenwald-based
E.DIS AG. The farm is equipped with eight N90 turbines and has
a total installed capacity of 18.4 MW.
The Ketzin wind farm is considered to be in a weak wind location.
To obtain optimal energy yield at such a location the machines
have been erected on tubular towers that are 100 metres
high. At this hub height the annual measured mean wind speed
is 6.3 m/s.
The 2.3 MW turbines that were especially developed for the
German market and installed here will generate approximately
35 million kW of electricity annually. This corresponds to the
annual power consumption of approximately 8,000 private
households in Brandenburg. What’s more, generating this
amount of electricity from wind prevents the emission of
30,000 tons of CO 2 that is harmful to the climate.
changer had to ensure the lowest possible
loss of pressure on the air side. Based
on the company‘s special expertise Küba
developed a prototype to re-cool the cooling
water.
How is this performed? The air inside the wind
turbine that is heated by generator losses is circulated
exclusively by the turning rotor. After its exit
from the stator package the air is forced through the
heat exchanger. The inner air which is re-cooled in this
manner is then rerouted into the areas of the two stator end
connections into the rotor. Both cooling flows (air/water) are
separate closed circuits. The warmed water and glycol mixture
is re-cooled by the outside air. At full generator capacity total
losses of up to 85 kW can occur on the generator. Additional
ribbing to cool the generator is not required.
Oliver Memminger, head design engineer for Winergy AG in Ruhstorf
values the collaboration with Küba: “In competing with other
well-known manufacturers, Küba Kältetechnik came through
as the winner due to their outstanding project work, high level of
flexibility, their high quality standard and their exemplary
documentation.” These prerequisites are mandatory
for series production. In addition, short response times
for all types of enquiries, the non-bureaucratic handling
of prototype orders, as well as the short delivery times
played an important role. “Küba‘s extensive know-how
was another decisive factor. Because all components
come from well-known certified manufacturers, we can
also guarantee high quality,” explains Memminger
with satisfaction.
➊ ➊
➊
in addition to the Küba cooled generator there are
17 different components in a wind turbine
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Uniformly well cooled
Room cooling can be easily and hygienically optimised with textile hoses from
Thermotex: Air is distributed in the room right where it’s wanted.
fReSH, cRiSP VegetABleS, tender steaks, or fine pastries
are appealing and they are what customers want. However in
the cooled work areas of the food industry one will frequently
find wilted lettuce, tough meat or dried-out baked goods. The
reason is usually non-uniform air distribution. This problem,
however, can be quickly and easily solved with a system based
on the textile hoses from Thermotex Luftleitsysteme GmbH in
Moers and evaporators from Küba. Air can be uniformly distributed
in the room with the hoses that are directly connected to
the evaporators. “In cooled work areas textile hoses currently
represent the state of the art”, confirms Rolf Otten, project engineer
for Linde AG headquartered in Wiesbaden.
This consistent use of textile hoses makes sense: All companies
that must cool their work areas for production require uniform,
low-draft cooling. Heat nests must be avoided. The combined
Thermotex/Küba system makes this possible and also has a
positive side effect: the working conditions for employees are
improved, resulting in lower illness rates. Accordingly, the hose
evaporator system has become a standard in the major logistics
centres of the food retail industry – for example, for Edeka,
Rewe or Tengelmann. Moreover, cooling the entire sales or work
area with this solution, instead of storing the goods that need
to be cooled in individual refrigerated shelves, is a solution that
implemented more and more. “The latter is another ideal application
for a system consisting of Küba evaporators and Thermotex
textile hoses,” explains Claudio Steinman, refrigeration
engineer TS at Frigo Consulting in Schlieren, Switzerland.
How does the solution function specifically? Air leaving the Küba
evaporator is channelled into Thermotex textile hoses and then
distributed throughout the room. The hoses are made of polypropylene,
a synthetic fabric that is characterised by its minimal
water retention capacity. At the end the hose is not sown shut,
rather it is stopped with a round end cap of the same diameter.
This produces a closed pressure system. Air escapes over the
entire surface of the hose at a speed of less than 0.2 m/sec. Water
condensation does not occur, since due to the air-permeable
fabric the temperature does not fall below the dew point. Compared
to insulated sheet metal ducting with air grills, this form
of air distribution is much easier and much more practical. It offers
even more advantages: Lower compression, lower weight,
faster installation and last but not least, a lower price. Furthermore,
the fact that the hoses can be cleaned and that they are
resistant to aggressive cleaning agents and lyes, makes them
an outstanding alternative to VA ducts.
Thermotex primarily develops industry-specific and custom
variants: “Our textile hoses are not off-the-shelf products; they
are each manufactured to customer order,” explains managing
director Jörg-Peter Krebs. Thus, the confectionary industry appreciates
the following solution: Thanks to fabric with differing
levels of permeability, the air escape direction can be guided
as needed in one hose. The upper half (9 to 3 o’clock) consists
of air-impermeable fabric; the lower half of the hose (3 to
9 o’clock) consists of permeable fabric. Thus, the air only flows
downward.
Just how individual a solution can be is demonstrated by this
actual case study: In the Tengelmann AG Logistics Centre in Viersen,
outside of Düsseldorf, the challenge was that there were
different ceiling heights in one room. In addition, due to the
remodelling in the course of expanding the warehouse, there
were main beams that ran in the air direction and shelving that
reached almost to the ceiling. Heinrich Kreutzträger Kältetechnik
GmbH & Co. KG, which has been relying on the Küba/Thermotex
combination for some time now, was commissioned to
optimise these rooms in terms of refrigeration engineering. The
experts sewed the textile hoses with height jumps and side
jumps. Now the air is distributed to two or three textile hoses
from one compressor, as needed. An optimal solution.
this is how it works (l. to r.): Hose adapter for compensating the
different heights (side view), hose piece at the transition point from
two hoses to one; two-motor Air cooler with thermotex textile hoses.
more information at: www.thermo-
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FORUM 01/2006
Self-serve shelves in front of the fish sales area co 2 -SgA 051 at 0 = 0 °c, for cooling the fish sales area
Best energy balance
In the branches of Aligro bulk supermarket, CO 2 is used as the refrigerant and comes out with significantly better
numbers than does the standard refrigerant R404A.
foR 30 yeARS, Aligro has been the undisputed number one
among the bulk supermarkets in French-speaking Switzerland.
The reason is the well thought-out retail concept that Aligro
founder Pierre Demaurex developed in the 1960‘s in Geneva and
which he consistently improved. The family-owned company
provides its customers, particularly restauranteurs and retailers,
not only top quality products in the greatest variety, Aligro “Alimentation
en gros” also features particularly customer-friendly
opening times: Its doors open to customers at 6:00 a.m.
Last fall, Dominique and Etienne Demaurex, sons and successors
of Pierre Demaurex opened the third Aligro market in Sion.
The typical Demaurex concept finds its successful implementation
on an impressive 5,000 m 2 sales floor (out of total floor
space of 12,500 m 2 ). Since freshness of the products is one of
the crucial quality parameters for Aligro markets, in Sion refrigeration
also played a decisive role. LKS KälteSchweiz AG/LKS
FroidSuisse SA, headquartered in Prattlen near Basel was re-
sponsible for planning and realisation of the overall refrigeration
and control technology in the normal area and deep freeze area
of the bulk supermarket. It is a subsidiary of the US firm, Carrier/Linde
Refrigeration. It supplied three compressor units, as
well as the cooling display cases with a total sales length of 180
m and equipped the nine walk-in cooling rooms with floor space
of approximately 200 m 2 . Moreover, Carrier/Linde Refrigeration
outfitted the five deep freeze cells with floor space of approximately
90 m 2 .
Technical details: For normal cooling, the new CO 2 composite cooling
system CO 2 OLtec by Linde Kältetechnik was used for the third
time. Control and monitoring of these NC compressor units, which
also work in the transcritical area, is also handled by the newly
developed Eckelmann VS3000C. All sales display case evaporators
and cooling room evaporators are equipped with electronic
expansion valves.
The required overall cooling capacity for the normal cooling area
is 322 kW. It is divided into two separate integrated refrigeration
units each with identical cooling capacity. The deep-freeze area
reaches a cooling capacity of 67 kW. Its heat is dissipated in
cascade operation by CO 2 evaporating directly from the normal
cooling systems. In the sales areas as well the direct expanding
carbon dioxide ensures heat dissipation in the normal as well as
in the deep-freeze area. A CO 2 gas cooler in V-block design is
used for transferring the heat (2 x 236 kW) that needs to be dissipated
to the ambient air. In the sales areas commercial retail
shoppers can find fresh and frozen goods in a variety of different
cooled shelving, cooling counters, cooling islands and deepfreeze
combinations from the Linde Evolution 5 series, as well
as in a larger number of walk-in cooling rooms and deep freeze
rooms. In these areas CO 2 Air Coolers from Küba are used exclusively.
A listing is provided in the table on page 22. In addition
heat recovery is integrated in the overall system concept. Thus,
hot water for heating at 2 x 150 kW is available during the heating
season and hot service water at 90 kW is available year round.
Some details concerning system installation and process control
for normal cooling: In the normal cooling system the compressor
unit system was divided into two pressure areas for
the dimensioning of components. The high-pressure area was
configured at a maximum operating pressure of 115 bar. This
area includes the pressure side of the compressors, the heat
recovery system, the hot gas and liquid line to the gas cooler,
all refrigeration components on the high-pressure stage, as well
as a special high-pressure valve. The maximum operating pressure
for the other system components, for example the collector
or the liquid and suction line, is only 40 bar. The evaporators
in the normal cooling system are optimised on the refrigerant
side for CO 2 for technical flow reasons and configured for the
higher pressure loads. Thus, for the greater part of the systems,
standardised commercial refrigeration components could be
used that among other things can also be used in CO 2 deep
freezing.
Other important issues when operating a compressor unit system
are the expenses for electricity. The refrigerant used is of
crucial relevance, particularly in this regard. If high outside temperatures
are assumed, then the standard refrigerant R404A
shows clear advantages in a superficial comparison of the refrigerants
R404A and CO 2 relative to achievable performance.
“However, if the favourable thermodynamic and technical thermal
characteristics of CO 2 are taken into consideration, there is
a different picture,” emphasises Marcus Höpfl, manager of the
Buchser subsidiary and member of the management team of
LKS KälteSchweiz AG. He explains:
• Due to better heat transfer ensured by CO 2 , it is possible to
operate refrigeration furniture or cooling room evaporators at an
evaporation temperature that is two Kelvin higher compared to
R404A.
• Due to the high pressure situation of CO 2 there is a saturation
temperature loss in the suction line that is reduced by one
Kelvin as compared to R404A. Thus, the return transport of the
oil to the condensers is further ensured in this process. The CO 2
condensers in the normal cooling system can be operated with
vacuum pressure, which corresponds in total relative to R404A
to a saturation temperature that is three Kelvin higher.
• The special characteristics of the transcritical process control
and the good heat transfer characteristics of CO 2 in the gas
cooler enable cooling of the pressure gas to nearly the air temperature.
• At lower air temperatures a reduction of the condensing temperature
to approximately +10 °C is possible when using CO 2 . The
reason is that a sufficiently high differential pressure exists relative
to the evaporation pressure due to the higher pressure level of CO 2
even at these low temperatures.
• The current energy consumption of NC/DF DX CO 2 systems
is approximately 15 to 20 percent lower than comparable NC
R404A-systems with refrigerant/re-cooling system and DF DX.
The energy data are based on measurements that have been
performed over a period of one to one and half years.
• At the current state-of-the-art the investment costs of NC/DF
DX CO 2 systems are equivalent to the cited comparable R404A.
The prerequisite is that the NC system performance must be
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FORUM 01/2006
co 2 -SAfety meASUReS: (l.) Bakery goods cooling cell with acoustic and visual signal if there is a co 2 alarm, as well as „Do not enter if
there is a co 2 alarm“ warnning sticker. (r.) After failure or standstill, all systems automatically start up again, even if the safety valve (as
shown in the photo) was active.
more than 220 kW or the surface area of the supermarket must
exceed 2,500 m 2 .
For Marcus Höpfl, the summary is clear: “CO 2 should be looking
at an exciting future as refrigerant. Currently its implementation
in refrigeration applications is indeed somewhat more expensive
because the necessary components are not yet being produced
in the same quantities as are produced for systems that
work with fluorinated refrigerants. Currently this acts as somewhat
of a brake on demand. In the future, however, there will
not be a price difference even at lower system capacities. Even
today, environmentally-oriented and energy-efficient companies
are converting to CO 2 and are setting positive examples. The
leaders are found in the Scandinavian countries and countries
like Switzerland, the Netherlands, Luxemburg, Saudi Arabia and
Germany.“
tHe tecHNology At A glANce
cooling rooms with co 2 supercritical and deep freeze rooms with co 2 subcritical. equipped with Küba co 2 evaporators.
Room Application evaporator capacity / kW t 0 /°c t R /°c P max bar
Cooling room NC Dairy S-SGBE 091 10.2 –5 +3/+5 54
Cooling room NC Unloading dock S-SGB 071 11.6 +3 +13/+15 54
Cooling room NC Intermediate storage S-SGB 061 8.0 +3 +13/+15 54
Cooling room NC Preparation S-SGB 041 2.9 0 +8/+10 54
Cooling room NC Intermediate storage S-SGBE 081 7.3 –7 0/+12 54
Cooling room NC Meat S-SGBE 061 4.0 –7 0/+2 54
Cooling room NC Meat preparation S-SGA 041 2.5 0 +8/+10 54
Cooling room NC Bakery S-SGBE 071 5.7 –7 0/+2 54
Cooling room NC Fish preparation S-SGA 051 3.9 0 +8/+10 54
Cooling room NC General S-SGBE 081 7.3 –7 0/+12 54
Cooling room NC Fish preparation S-SGA 051 3.9 0 +8/+10 54
Cooling room NC Fruits & vegetables S-SGB 091 10.2 –5 +3/+5 54
Cooling room DF Deep-freeze room S-SGLE 082 C 10.5 –31 –22/–24 32
Cooling room NC Deep-freeze room S-SGLE 082 C 10.5 –31 –22/–24 32
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On March 16th 2005, the Act Governing the Sale, Return and Environmentally Sound Disposal of Electrical and Electronic Equipment
(ElektroG) went into effect in Germany. Thus, two EC directives that are important for the refrigeration industry were also implemented
in German national law: Directive 2002/96/EC concerning Waste of Electrical and Electronic Equipment (WEEE), as well
as directive 2002/95/EC concerning the restriction of certain hazardous substances in electrical and electronic equipment (RoHS).
To what extent is Küba affected by the new directives? Are Küba products subject to the new ElektroG and, if yes, which ones? Do
cooling systems that are equipped with Küba heat exchangers fall under the ElektroG?
tHe AReA of APPlicABility of the ElektroG includes large
and small household appliances (e.g. refrigerators, mobile room
air conditioners) that require electrical current or electromagnetic
fields for their operation. On the other hand, the ElektroG does
not apply to these units or components if they are connected to
units that are not themselves subject to the ElektroG (for example,
room air conditioners that are permanently installed in the
building, as the building is not subject to the ElektroG), or units
that are only installed by specialised personnel (e.g. cooling systems).
• Evaporators, Air Coolers, condensers and re-coolers, which
are indeed equipped with fans, are not considered electrical
equipment in terms of the ElektroG, because they are installed
by specialised personnel in stationary cooling systems. The
cooling system is permanently connected to the building.
• Heat exchangers are not classified as electrical equipment
subject to the ElektroG, rather they are considered to be
components. Only if these components are installed in units
which themselves are subject to the ElektroG, (e.g. coolers
in large household appliances), must the ElektroG be taken
into account relative to the restrictions on the use of certain
hazardous substances such as lead, mercury, chrome or cadmium.
Heat exchangers in permanently installed systems are
not subject to the ElektroG.
• Likewise, refrigeration or air-conditioning products such as
are installed in vehicles or in refrigerated sales display cases
do not fall under the ElektroG (see the ORGALIM manual for
WEEE and RoHS).
Küba heat exchangers and units are designed for permanent industrial
cooling systems that are installed by specialised personnel
and thus are not subject to the ElektroG. Nevertheless, for
the materials, solder or welding additives and purchased parts
used by Küba, certificates are available stating that these materials
or parts are RoHS-compliant. While Küba heat exchangers
are not subject to the ElektroG, they nonetheless satisfy both
RoHS and ElektroG requirements.
moRe iNfo
FREQUENTLY ASKED QUESTIONS
http://www.kueba.com/kueba/deutsch/nbsp/menu/what_146_s_
new/aktuelles/aktuelle_vortraege/elektrog/index.html
01/2006 FORUM