Case Study: DINBO Mushroom Farm – How to Properly Select and Adapt a Chiller for Mushroom Cultivation

Emerson 482 kW Chiller with Free Cooling for DINBO Mushroom Farm

How EVROPROM Adapted and Commissioned a Cooling System for Large-Scale Champignon Cultivation

In mushroom farming, climate control isn’t just about comfort — it directly determines yield. The more precise the microclimate regulation, the higher the biological efficiency, growth stability, and commercial quality of champignons.

At DINBO farm — one of the largest mushroom producers in Western Ukraine — up to 12 tons of product are harvested daily. The facility operates 24 climate-controlled chambers with a total volume exceeding 12,000 m³ and has been active on the market for over 14 years. Temperature stability in these growing rooms not only minimizes losses but also enables record-breaking yields.
For this task, EVROPROM delivered a complete cycle of selection, adaptation, and commissioning of an Emerson SLS 0540 chiller with a cooling capacity of 482 kW, dual-circuit configuration, and integrated free cooling for energy-efficient operation at outdoor temperatures below +10 °C.

About the Client: DINBO Mushroom Farm

DINBO is a modern mushroom farm founded by the Bobrovsky family 14 years ago in the village of Shpytky, Kyiv region (Kyiv-Sviatoshynskyi district). Over the years, the farm has earned a reputation as one of the most respected and technologically advanced producers of champignons and oyster mushrooms in Ukraine.

The facility operates 24 full-scale cultivation chambers, and processes more than 400 tons of compost per month. With up to 12 tons of fresh mushrooms harvested daily, DINBO is a key player in the national market.

The core philosophy of the company is built on ecological sustainability, natural processes, and modern technologies. DINBO’s mushrooms are free of pesticides, GMOs, growth stimulants, nitrates, and antibiotics — making them safe even for children. Thanks to precise climate control, strict hygiene standards, and automated operations, the farm consistently delivers clean, fresh, and flavorful products.

DINBO follows European production standards, with a multi-level microclimate management system in all chambers. Even minor fluctuations in temperature and humidity are accounted for in the cultivation cycle.

This project wasn’t the farm’s first collaboration with EVROPROM — the first Emerson chiller was installed at their site in Odesa. The second unit was delivered and commissioned for their flagship location in Shpytky — both used to cool compost during the 3rd phase and maintain stable temperatures during the fruiting cycle.

Why the Emerson SLS 0540 Chiller Was Chosen

In mushroom cultivation, climate control isn’t just comfort — it’s productivity. From the very first hours of incubation, mycelium responds to precise temperature signals. During colonization, it’s crucial to gradually lower the temperature from 22 °C to 18 °C, simulating natural conditions. This stepwise transition (21 → 20 → 18 °C) triggers fruiting. Later, during harvesting, maintaining cool air prevents discoloration and preserves the mushrooms’ freshness and visual quality.

To support such a precise process, the Emerson SLS 0540 was selected — a chiller with proven performance in industrial environments. The unit provides:

• Cooling capacity: 482 kW at a water outlet temperature of +6 °C, with the ability to adjust down to –5 °C for compost cooling and cold shock conditions.
• 2 Bitzer screw compressors with stepless capacity control from 50% to 100% — enabling stable water temperature regulation.
• Free cooling system with a 210 m² heat exchange surface, delivering up to 450 kW of thermal capacity at outdoor temperatures below +5 °C — covering up to 30% of the annual operating time and significantly reducing electricity consumption.
• Shell-and-tube evaporators (12 m² per circuit) — ensuring high heat exchange efficiency and long-term reliability.
• 6 axial fans (0.75 kW each) with variable speed control — adapting to environmental loads.
• Smart controller — configurable for cascade or stand-alone operation, supporting Modbus integration and pressure safety setpoints up to 25 bar (condensation) and 0.8 bar (evaporation).

After adaptation, the chiller was recalibrated for operation at +40 °C condensing temperature under +35 °C ambient conditions, ensuring resilience even in peak summer heat.

Designed for continuous 24/7/365 operation (up to 8760 hours per year), the Emerson SLS 0540 became the core of the climate stability system at DINBO.

Thanks to its precise configuration and efficient free cooling integration, this chiller delivers:

• Stable water temperature control with ±0.2 °C accuracy, regardless of external conditions.
• Up to 30% energy savings through optimized seasonal operation.
• Reliable performance under continuous industrial load.
• Fast responsiveness to changing production needs, ensuring flexibility and uptime.

Chiller Adaptation and Commissioning

Before being delivered to the DINBO facility, the Emerson SLS 0540 had operated as a slave unit in a cascade configuration of four chillers. It lacked autonomous control — compressor startup was disabled by the controller unless commanded by the lead chiller.

To prepare the system for stand-alone industrial operation, the EVROPROM engineering team performed a full reconfiguration:

• Firmware reprogramming of the controller to remove cascade logic and activate stand-alone mode.
• Reconfiguration of temperature setpoints — adjusted from +6.5 °C to –5 °C, matching the requirements of the compost cooling process.
• Programming of safety thresholds — including refrigerant pressure, oil temperature, and discharge temperature protection.
• Refrigerant charge correction — using electronic scales, each circuit was charged with 80 kg of R134a.
• Vacuuming of the refrigerant circuit — pressure reduced below 2 mbar and leak-tested with nitrogen at 20 bar.
• Free cooling logic setup — enabling partial mode below +10 °C and full transition below +5 °C ambient temperature.
• Workshop testing — each circuit was loaded up to 240 kW, achieving stable +6 °C water outlet temperature within 12 minutes.
• Failure simulations — including sensor disconnection, fan shutdown, and overpressure triggers. All protections responded as expected.

Testing and Final Commissioning

Each of the two refrigeration circuits underwent comprehensive testing with logging of key performance parameters:

• Chilled water outlet temperature: +6 °C under nominal load
• Condensing pressure: 14 bar at +35 °C ambient air temperature
• Evaporating pressure: 1.8 bar at +6 °C water outlet temperature
• Compressor oil temperature: +55 °C
• Compressor current draw: 130 A under full load
• Free cooling capacity: 420 kW at +3 °C ambient air

Upon completion of all procedures, the Emerson SLS 0540 chiller was fully commissioned and ready for 24/7 industrial operation:

• Operates in autonomous mode with complete free cooling logic enabled
• Both circuits charged with refrigerant to within ±0.05% accuracy
• Full technical documentation and test protocols were prepared and delivered
• The entire preparation process — from technical task approval to dispatch — took 14 calendar days

Conclusion

For a mushroom farm operating under continuous 24/7 load, a reliable chiller is not a luxury — it’s a critical part of the production chain. Temperature control directly impacts biological efficiency, harvest volume, and product quality.

Following EVROPROM’s full-cycle adaptation, the Emerson SLS 0540 now delivers:

• Precision cooling with ±0.2 °C water temperature stability
• Up to 30% energy savings through free cooling operation
• Full compatibility with the farm’s agro-cycle, including shock cooling and staged temperature reduction during incubation and harvesting phases
• 24/7 operational reliability backed by full diagnostics and test protocols

Looking for a dependable chiller with free cooling capability? Need a custom-engineered HVAC solution for your food or agricultural facility?

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