626 kW Lennox Chiller for ALFA S.A: Stable Cooling for Beverage Bottling Line

ALFA S.A: Cold as a Point of Technological Balance in the Albanian Beverage Market

In the world of high-tech industrial refrigeration, the ability to control process parameters with absolute precision is a key competitive advantage.

For ALFA S.A, a beverage production company in Albania, stability and predictability of temperature regimes have become the cornerstone of product quality and operational success.

ALFA S.A is no newcomer to working with EVROPROM. The company had previously entrusted us with the delivery of similar high-tech equipment, including an air-cooled chiller — the Clivet WDAT-IL3 360.2. That experience allowed us to gain deep insight into their technological requirements and propose a solution that exceeded expectations in both performance and reliability.

The repeated purchase of a Lennox NAC640D chiller became a natural continuation of this fruitful partnership. Our understanding of ALFA S.A’s production processes, their high quality standards, and the dynamics of the beverage market enabled us to fine-tune the system to the highest level — down to the individual configuration of controllers and compressor control parameters.

Technology Crossroads: Why the Lennox NAC640D Outperformed the Clivet WDAT-IL3 360.2

The 802 kW air-cooled Clivet chiller had been the plant’s workhorse. However, its system architecture — designed in the 2010s — featured staged compressor control, fixed-speed fans, and high peak load characteristics. These posed limitations in the context of modern, dynamic production processes.

The Lennox NAC640D marked a significant upgrade due to the following:

• Frequency-controlled operation of six Copeland compressors allows smooth modulation of cooling capacity from 15% to 100%, significantly reducing energy consumption under partial load. 
• Maximum noise levels were reduced from 78 dB(A) to 69 dB(A), improving the indoor climate and working comfort. 
• Energy Efficiency Ratio (EER) increased by 27% — from 1.21 (Clivet) to 1.54 (Lennox), which translates into considerable energy cost savings. 
• Intelligent automation ensures ±0.1 °C temperature accuracy — a critical parameter in beverage production cycles. 

Compressor Technical Analysis: The Cold Heart’s Engine Room

The six Copeland ZP485KCE-TWD-524 scroll compressors are the key to the system’s flexibility and reliability. Each unit delivers approximately 105 kW of cooling, collectively providing 626.9 kW across two refrigeration circuits.

Technical features of the compressors:

• Current runtime: approx. 4,200 hours, out of a design life of 48,000 hours, ensuring up to 10 years of operation under standard load. 
• Variable-frequency drives (VFDs) enable low-noise operation and reduce inrush current, minimizing electrical wear. 
• Integrated protection systems against overheating and oil pressure imbalances extend service life and operational safety. 

Hydraulics and Heat Exchange: The Invisible Foundation of Stability

The WILO IL80/160-11/2 pump ensures a flow of up to 160 m³/h at a pressure head of 11 bar, maintaining a 5–6 °C temperature differential across two independent circuits serving the filling, storage, and raw material preparation areas.

Plate-type evaporators with a heat exchange surface of over 6.3 m² per circuit provide:

• Minimal hydraulic resistance, reducing energy consumption of the pump group. 
• Stable heat transfer — essential during sudden or constant changes in process load. 
• Fast response to control system inputs, enabling precise and dynamic temperature adjustments. 

Condensers and Refrigerant: The Technical Magic of Heat Rejection

Microchannel aluminum condensers, with a total surface area of 84 m² and ten 2.2 kW fans, provide:

• Intense heat rejection under any climate conditions — especially vital in Albania due to seasonal temperature fluctuations. 
• Variable fan speed control via VFDs, achieving up to 18% energy savings in cooler months. 
• Full-load operation reliability without risk of overheating. 

The R410A refrigerant (charge: 45 kg) ensures:

• High thermal conductivity and stable phase transition. 
• Full compliance with EU environmental regulations (ozone safety and low GWP). 
• Optimal pressure levels: 26.1 bar on discharge and 7.9 bar on suction — aligned with compressor specs. 

Automation and Control: The Chiller’s Central Nervous System

The intelligent controller of the Lennox NAC640D supports:

• Modbus and BACnet protocols for integration with higher-level systems like SCADA and EMS. 
• Temperature control accuracy of ±0.1 °C, with automatic recalibration in response to process changes. 
• Real-time equipment monitoring with alerts for potential failures. 
• Redundant operation and safety overrides for continuous cooling even in case of individual circuit faults. 
• Adaptive control of fan and pump speed for optimized power consumption. 

Logistics and Installation: When Speed and Quality Matter

EVROPROM delivered the Lennox NAC640D directly from Poland with full technical documentation and warranty coverage. Delivery time: 9 days. Installation and commissioning: 6 hours, allowing for seamless integration into ALFA S.A’s production workflow.

Additional highlights:

• Refrigeration system integration with the existing Clivet WDAT-IL3 360.2 unit was completed in compliance with environmental standards. 
• Commissioning included configuring system parameters to meet production requirements, adapting the controller for local conditions, and load testing. 
• The system underwent full vacuuming and refrigerant charging, verified by protocols and technical inspection reports. 

What the Numbers Mean: Performance That Drives Competitive Advantage

• 626.9 kW of cooling — optimized for ALFA S.A’s specific production demand. 
• 4,200 hours of compressor runtime — guaranteeing stable long-term operation. 
• 0.65 kW of electrical consumption per 1 kW of cooling — a 25% reduction in energy costs compared to the previous system. 
• ±0.1 °C temperature accuracy — critical for ensuring beverage consistency and quality. 
• 11 bar pump pressure — maintaining uniform heat exchange and system balance. 
• 6.3 m² heat exchange surface per circuit — ensuring low hydraulic resistance and fast system response. 

Conclusion: Why Technical Excellence Is the Key to ALFA S.A’s Success

The engineering leap achieved with the Lennox NAC640D chiller represents more than a transition to modern equipment — it is a strategic response to the evolving demands of the beverage market. In this sector, every degree of temperature and every kilowatt of energy directly affect product quality and operational economics.

ALFA S.A now benefits from a system that:

• Adapts flexibly to fluctuating loads thanks to six frequency-controlled compressors. 
• Maintains thermal stability with extreme precision, minimizing process risks. 
• Significantly reduces energy costs and environmental impact. 
• Seamlessly integrates into existing plant management systems, creating a unified digital environment. 

Like a precision instrument, the Lennox NAC640D has become an essential part of ALFA S.A’s production ecosystem — delivering cold, stability, and confidence at every step of the process.

This is an investment not just in equipment — but in reliability, quality, and the future of the company.

Author:
Sviatoslav Ovcharenko, Sales Manager
Date: July 17, 2025