Poultry Processor Multi-Phase Expansion
Scenario
A poultry processor in Gainesville, Georgia needed to expand fresh and frozen production without interrupting ongoing operations. The project required extensive refrigeration modifications across multiple buildings, completed in over eight construction phases. Room refrigeration fed from engine rooms slated for demolition had to be relocated and tied into new and existing systems. The priority was to maintain consistent environmental conditions and keep production running throughout the entire project.
Challenges
The project required relocating room refrigeration from engine rooms being demolished into new or existing engine rooms, with extremely limited downtime allowed.
Coordinating work across eight building phases added complexity as areas were simultaneously rebuilt, expanded, or taken offline temporarily.
Transitions between old and new systems needed to occur seamlessly, with minimal interruption to production.
Project scope evolved, requiring continual redesign and budget reviews.
Three separate refrigeration systems needed to be brought into one centralized control platform, supported by a new communication infrastructure.
A narrow VRT valve corridor required placement of 12 valve groups in a way that preserved safe working clearance for technicians.
Moisture entering the -35°F VRT freezer caused ice buildup on drives and equipment, requiring frequent maintenance and reducing operational reliability.
Our Solution
Sterling developed a relocation plan that allowed room refrigeration equipment to be moved out of the engine rooms scheduled for demolition with minimal pump-downs and tie-ins. Temporary operating strategies reused materials where possible, reducing cost and improving safety.
A safe layout for the VRT valve corridor was engineered so technicians had adequate space for service and a clear retreat path in the event of ammonia detection. Ventilation was added and tied to temperature and ammonia sensors.
Moisture infiltration into the VRT freezer was significantly reduced by installing a dehumidification unit outside the room.
Penthouse units were used in equipment-dense areas to reduce clutter and avoid interferences with normal operations.
Hygienic rooftop air handlers supported rooms with exposed product, improving temperature consistency and airflow quality.
All remote units were connected through fiber communication to support a unified control platform.
Weekly coordination meetings with all trades ensured safe scheduling of crane lifts, demolition activities, equipment placement, tie-ins, and commissioning events.
Sequencing work in this manner helped maintain compliance with safety requirements throughout construction.
KPI's
PROJECT PHASES
8 PHASES COMPLETED
Refrigeration maintained throughout construction
Refrigeration maintained throughout construction
MOISTURE REDUCTION
SIGNIFICANT REDUCTION IN ICE BUILDUP
Reduced maintenance requirements
Reduced maintenance requirements
PROJECT DURATION
2022-2026
Executed while supporting active production
Executed while supporting active production
throughput of vrt
1.5M LBS/DAY
REFRIGERATION CAPACITY ADDED
660 TONS AT -45 DEGREES F