Two Carrier Chillers for Oscar Chocolates Factory in Greece

Oscar Chocolates is a manufacturer with a twenty-year history and an annual production of over 12,000-18,000 tonnes of semi-finished chocolate products, serving the EU and Middle East markets. The main factory is located in Greece, in the central region, where the production lines have a capacity of over 2.4-3.1 T/h depending on the type of mix. The Thessaloniki branch serves the north of the country and provides distribution to warehouses in Larissa and Ioannina with a total storage capacity of over 4,500 pallet spaces, which maintains supply stability for large B2B customers. Production chains include chocolate masses, glazes, fondants, tempered mixes and OEM products for biscuit factories and ice cream manufacturers. Some 35-40% of production is exported, and the lines operate in three shifts – up to 22 hours of effective time per day.

Oscar Chocolates’ process cycle demands a level of laboratory precision. Melting takes place at 40-52 °C, conching operates between 55-65 °C with a heat output of up to 180-240 kW per line, vacuum mixing requires stable cooling with an accuracy of ±0.2-0.3 °C, and the final tempering process is critical at 28-32 °C with a tolerance of no more than ±0.3 °C. Cooling after conching – the reduction from 45-60 °C to 28-30 °C – must occur strictly within 6-11 minutes, otherwise the chocolate loses its correct β-crystalline HVAC structure.

The cooling jackets of the containers consume up to 1.8-2.5 m³/h per circuit and the circulation pressure must be kept between 1.4-1.9 bar, otherwise the viscosity of the mass, 2,500-6,200 cP changes and the process becomes unpredictable. Any deviation – even a short-term temperature jump of 0.6-0.9 °C, a drop in flow rate below 1.7 m³/h, or a pressure fluctuation above 2.1 bar – leads to process defects: white fat, micro-bubbles, matt surface, incorrect geometry or crystal mesh failure. This is a direct loss of raw materials and quality, reaching 5-12% of the batch. Oscar Chocolates selects equipment not on the principle of cost, but in the fact of engineering suitability, the ability and suitability of the chiller to handle viscous products, high thermal inertia and all temperature tolerances in an industrial facility.

Laboratory requirements governing the operation of confectionery equipment in industrial parallel with HVAC equipment

Tempering is a key stage of production where any error is immediately reflected in the quality of the product. If the actual temperature deviates by as little as 0.3-0.5 °C, the formation of stable β-crystals of cocoa butter is disrupted, resulting in structural breakdown, loss of lustre, lack of brittleness and surface defects as early as 1 to 3 hours after cooling. Chocolate masses with a viscosity of 2,500-6,200 cP have a high thermal inertia and therefore require perfectly uniform cooling in the range of 8-12 °C, with a permissible gradient of distribution of no more than ±0.2 °C over the heat transfer surface. If cooling is more uneven than 0.6-0.8 °C, the chocolate changes shape, crystallisation occurs, areas of severe cooling and geometric disturbances occur, resulting in loss of marketability.

Important parameters for process cooling:

– Feeding stability of 7-12 °C with a deviation not exceeding ±0.3 °C, as even a short-term departure of 0.4-0.6 °C causes disruption of β-crystal formation and changes in the texture of the mass;

– Staticity of circuits without pressure jumps above 2.0-2.2 bar, as pressure increase leads to local overheating of jackets and disturbance of chocolate viscosity in working vessels;

– Uniform circulation at a flow rate of 4.5-6.8 m³/h per node, which eliminates the formation of temperature gaps and ensures a uniform cooling rate across the entire heat exchange surface;

– Low vibration of compressors not exceeding 1.5 mm/s, as vibration vibrations are transmitted to the circuit and disturb temperature stability in sensitive tempering processes;

– Absence of micro-pulsations of temperature during start-up and shut-down of the equipment, where even a jump of 0.2-0.3 °C can disturb the uniformity of crystallisation in the first layers of the chocolate mould.

If the chiller allows a temperature jump of 1.8-2.3 °C, the chocolate in the moulds cools unevenly. This results in grey deposits, voids in the structure, irregular geometry and defects.

The requirements for cooling equipment in chocolate factories are therefore much stricter than in most food processing plants, where temperature tolerances can be as wide as ±2-4 °C.

The combination of the financial transparency of the transaction, the diagnostics and the condition of the chillers, which generated a repeat order from EVROPROM

The company has made 2 chiller purchases just a few months apart – and each was based on a clear engineering logic related to increasing production volumes and increasing heat load on the tempering line, where the total heat input exceeds 310-420 kW.

The first order – Carrier 30RB0232, 227 kW – was aimed at stabilising the current cooling chain; the second order – Carrier 30RB372, 367 kW – provided an expansion of the production unit and additional temperature reserve with a refrigeration capacity of 110-140 kW.

Reasons why the plant in Greece chose EVROPROM twice:

– Low and validated motor hours reflecting easy operation of the equipment, as the first chiller had values of 1020 / 966 / 758 / 768 h and the second chiller had values of 1751 / 1577 / 1704 / 1454 / 1299 / 1492 h, 60-70 % below the market average for 2011-2012 units;

– High temperature stability without deviations above ±0.3-0.4 °C, as confirmed by EVROPROM tests at supply 7-12 °C and return 12-17 °C, with ΔT 5.0-5.3 °C and pressure retention in the ranges of 8.1-8.6 bar at suction and 29.0-31.4 bar at discharge in cooling;

– Accurate operation on R410A at low boiling gradients of -2…3 °C, ensuring a stable heat transfer coefficient, low vibrations of 0.8-1.4 mm/s, and energy efficiency in 30…35 °C regimes characteristic of the variable climate of the region of central Greece;

– The reliability of Danfoss SH240A and SH300 compressors, designed for 200,000-250,000 switching cycles, with 27-34 A load, 120-148 A starting currents and a lifetime that maintains efficiency even with continuous operation up to 22 hours per day without temperature spikes;

– Carrier’s second Carrier microchannel condenser, which provides an 11-14% increase in energy efficiency in summer at ambient temperatures of 33…37 °C, due to the increased heat exchange area and higher heat transfer coefficient of the chiller’s aluminium channels;

– Complete absence of problems during 24/7 operation under 180-260 kW load, confirmed by EVROPROM tests on 8 parameters: flow rate 17-22 m³/h, vibration, current, pressure, liquid temperature 38-42 °C, fan uniformity 2500-2800 m³/h per section;

– One hundred per cent transparency of EVROPROM diagnostics, including measurement records of 40 values, bench tests on water, video and photo evidence, vibration, pressure, temperature, current and data measurements for all six compressors, eliminating any doubts.

Oscar Chocolates chooses equipment based on real measurements, numbers and technical performance – and two consecutive orders from EVROPROM were a direct confirmation of trust based on applied facts.

Carrier 30RB0232 – 227 kW, parameters, engineering stability and actual suitability for an operational line in the centre of Greece

The Carrier 30RB0232 with a cooling capacity of 227 kW proved to be the optimal solution for the current Oscar Chocolates cycle, where the total heat load of the tempering and conching line was 170-190 kW with peak pulses up to 205-212 kW. The 2012 model, equipped with four Danfoss SH240A compressors, showed an atypical condition for equipment of this age: motor hours of 1020 / 966 / 758 / 768, which is about 2.8-3.4 times lower than the market average for the second-hand segment. On EVROPROM tests, the unit maintained a stable suction pressure of 7.8-8.4 bar, discharge pressure of 29.2-31.0 bar, fluid temperature of 37-41 °C, and vibration remained within 0.9-1.2 mm/s. The shell-and-tube evaporator provided uniform heat transfer at ΔT of 4.6-5.1 °C, which is critical for masses with viscosities of 2,500-6,200 cP. The power supply remained stable: load current 31 A per compressor, cosφ 0.83-0.87, inrush currents up to 132 A.

In real conditions, the chiller showed complete stability: the supply temperature remained within the range of 7.1-7.4 °C, the return – 12.0-12.4 °C, and deviations did not exceed ±0.3 °C, even in moments of sharp changes in the thermal balance. Operation in the Greek winter climate at 2…7 °C activated the freecooling mode, providing energy savings of 20-30 %, reducing the load on the compressor section and reducing the annual consumption by 11,000-15,000 kW/h. The chiller operated with synchronous behaviour of the circuits, zero HP/LP errors and no pressure surges. The actual stability of operation was a decisive factor in convincing Oscar Chocolates to expand the chiller system in the future.

Carrier 30RB372 – 367 kW, proven thermal stability and ability to operate in the growing production HVAC cycle

The 367 kW Carrier 30RB372 was selected during a production scale-up period when the new refrigeration line required a guaranteed capacity of 320-340 kW and an additional 30-45 kW of thermal reserve. The 2011 unit, equipped with six Danfoss SH300/SH240 compressors, showed a uniform condition across all components: 1751 / 1577 / 1704 / 1454 / 1299 / 1492 engine hours, indicating uniform operation without additional loads. The use of a microchannel aluminium condenser provided an 11-14% improvement in energy efficiency at air temperatures of 33 … 37 °C, typical of the Greek summer. In EVROPROM bench tests, the second chiller showed suction pressures of 8.1-8.6 bar, discharge pressures of 28.8-31.2 bar, liquid line temperatures of 38-42 °C, vibrations of 0.8-1.4 mm/s, and water flow rates kept at 17-22 m³/h at differential pressures.

In production, the device ensured stability of the critical tempering range of 28-32 °C with an accuracy of ±0.3 °C, preventing disturbances in cocoa butter crystallisation that occur with fluctuations greater than 0.5-0.7 °C. Balanced circuits prevented overheating, and the precision of the automation allowed the temperature to be kept exactly within the process corridor, even with load spikes of up to 8-12 % per minute, which is typical of high capacity HVAC temperature control units. Low vibration levels of 0.8-1.4 mm/s confirmed the absence of mechanical wear on the scroll compressors.

The final tests showed a willingness to operate for up to 22 hours, maintaining a stable cooling cycle with no emergency blockages and no loss of efficiency. For Oscar Chocolates, this means future scalability, redundancy and independence of production lines.

Carrier’s dual-circuit design as the basis for fault tolerance and stable thermal balance at a chocolate factory in Greece

– Two independent circuits retain 48-52 % of capacity in the event of a single circuit failure, keeping tempering within a tolerance of ±0.3 °C and preventing batch rejects worth €3,000-12,000;

– Danfoss SH240/SH300 compressors provide 0.8-1.4 mm/s vibration, soft starting currents of 120-148 A and viscous mass stability of 2,500-6,200 cP during long conching cycles;

– R410A operation keeps boiling within a narrow range of -2 … 3 °C, ensuring uniform heat dissipation from the chocolate when the temperature drops from 60 °C to 28-32 °C without sudden jumps;

– Microchannel condenser reduces discharge pressure by 12-17 %, keeping it in the range of 28.8-31.2 bar even at air temperatures of 35 °C and preserving compressor life;

– Uniform cooling eliminates white scale formation, preventing overheating above 33.5 °C and subcooling below 27.5 °C on moulds and tank jackets;

– Freecooling provides savings of 20-30 % in winter, reducing the load on compressors at 2… 7 °C and reducing consumption by 11,000-18,000 kW/h per month.

EVROPROM’s service preparation as a complete engineering cycle of checking and reconditioning of the equipment before actual shipment

– Vacuumisation to 280-310 microns with a holding time of 40-55 min, eliminating moisture and the risk of ice formation at temperatures of -2 °C;

– R410A filling with ±20-30 g accuracy, circuit parameters: suction 7.8-8.6 bar, discharge 28.8-31.2 bar at load;

– Danfoss compressor check: operating current 27-34 A, starting current 120-148 A, phase deviation < 1 %, all windings uniform;

– Test of 8 parameters under load: flow rate 17-22 m³/h, ΔT 4.8-5.3 °C, boiling -2… 3 °C, automatic operating points without errors;

– Vibration monitoring 0.8-1.4 mm/s, no bearing wear, shock peaks or resonance frequencies;

– Pressure balancing of circuits: difference < 0.3-0.4 bar, correct operation of oil balance and uniform cycling;

– Calibration of NTC sensors ±0.2 °C, confirmation of 28-32 °C range stability on test cooling;

– Fan check: 2,500-2,800 m³/h, current 1.8-2.3 A, rated RPM, uniform blowing of sections;

– Condenser leak test at 29-31 bar, no pressure drop for 20-25 min;

– Protocol of 40 measurements including currents, pressures, vibrations, temperatures, superheat 4.5-6.1 K, subcooling 2.8-3.6 K.

EVROPROM logistic realisation, accelerated preparation of delivery and commissioning of chillers without loss of time and budget

– Complete preparation of both chillers in 7 days instead of the standard 120-180 days, including service, tests, packaging and protocols – saving 113-173 days of production downtime;

– Full customs clearance at EVROPROM’s expense, where the customer avoided 450€-700€ and additional 2-4 days delays in paperwork;

– Shipment without a single delay, adhering to schedule, loading windows, route and axle load requirements, eliminating carrier penalties;

– Delivery to Greece exactly at the declared time, with control of GPS-route, fixation of coordinates every 20-30 minutes and no deviations from the route;

– Commissioning of the equipment 2-5 hours after arrival, thanks to pre-wiring preparation, port labelling and provision of a technical protocol to the customer.

Oscar Chocolates’ holistic benefit – proven efficiency gains, economic returns and technological reserve

– No temperature deviations in the 28-32 °C range with an accuracy of ±0.3 °C, which reduced the reject rate by 10-15%, saving the company €3,000-12,000 per cycle thanks to the precise and stable crystallisation of cocoa butter and the elimination of local mould overheating;

– Engineering stability 24/7, confirmed by test parameters: vibration 0.8-1.4 mm/s, suction 7.8-8.6 bar, discharge 28.8-31.2 bar, flow 17-22 m³/h, ΔT 4.8-5.3 °C, liquid temperature 38-42 °C – each parameter within the previously agreed norm;

– EVROPROM warranty for 6 months including coverage of Danfoss compressors, fans, NTC sensors, automatics, start-up protection modules, and on-site adjustment of parameters after start-up with no additional costs to the customer in the future;

– Testing of 8 key parameters under load, including pressure, flow, temperature, currents, vibrations, ΔT, automation and fan operation; a protocol of 40 measurements confirmed that both chillers were ready for operation without limitations in dynamic integration;

– Reduction of monthly raw material losses by 5,000€-9,000€ thanks to the precision of cooling masses with a viscosity of 2,500-6,200 cP, where any temperature jump of more than 0.5-0.7 °C leads to structural defects;

– Obtaining a real temperature capacity reserve of 48-52 %, which completely eliminated production stoppages and saved 12,000€-20,000€ on each downtime at a line hour cost of 300€-600€;

– Reduction of energy consumption in the winter season by 20-30 % due to free-cooling, providing savings of 11,000-18,000 kW/h per month, with an outside temperature of 2… 7 °C and load reduction;

– 18-25 % increase in process cycle performance after the second chiller was commissioned, which became possible due to stable distribution of 320-340 kW of heat loads and absence of drops;

The client received a complete documentation package: bench test report with 40 parameters, certificates and data sheets, customs files and CMR without delays, 29-31 bar leakage certificate, wiring diagrams and port labelling for quick installation, ventilation data 2,500-2,800 m³/h, confirmed scroll compressor hours and commissioning instructions with setpoints without integration pauses.

Bottom line: measurable stability, capacity gains and direct financial benefits for Oscar Chocolates from EVROPROM

In chocolate production, where a tolerance of ±0.3 °C determines the quality of the entire batch, Carrier’s 227 kW and 367 kW chillers strengthened the process line with cooling accuracy, loop stability and the ability to maintain a 28-32 °C range without spikes. Thanks to the service, 40 parameter tests, fast logistics in 7 days and commissioning in 2-5 hours, the factory achieved stable tempering, an increase of 18-25 % in productivity and a 10-15 % reduction in scrap. Winter savings from free-cooling amounted to 11,000-18,000 kW/h and the avoided downtime saved the company potentially €12,000-20,000. Together, the solution gave Oscar Chocolates sustainable growth and direct financial benefits, confirmed by HVAC application metrics.

Contact EVROPROM for an optimised and cost-effective choice:

🌐: evroprom.com

📞: 48 799 355 595

📥: sales@evroprom.com

Author of the article:
Svyatoslav Ovcharenko, sales manager
28.11.2025