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Facility background
Zott SE & Co. KG operates dairy production facilities across Europe, producing milk, cheese, cream, yogurts and desserts under brands including Monte, Jogobella and Zottarella. The company's main plant in Mertingen, Germany, includes cooling tunnels essential for product quality.
Built in 1989, these cooling tunnels required continuous operation to preserve dairy products. After more than 30 years of service, the original fan systems demanded replacement to maintain production reliability.
Project achievements
Achieved through high-efficiency ZerAx® fan replacement across five cooling tunnels
Total energy savings across all five cooling tunnels supporting continuous dairy production
Operating cost reductions delivered rapid return on investment through reduced energy consumption
Complete replacement across five cooling tunnels whilst maintaining production schedules
Operational challenge
The aging fan systems created multiple operational risks:
- High energy consumption increased facility costs
- Frequent maintenance interrupted production schedules
- Limited control options prevented automation integration
- No redundancy provisions threatened production continuity
Equipment failures in a 24/7 facility risked product spoilage. Sourcing replacement parts became increasingly difficult as components reached end of life. For temperature-critical dairy processes, reliable cooling performance was the primary concern.
Technical specification
- 120 ZerAx® high-efficiency axial fans
- Adapter plates for mounting to existing infrastructure
- Short diffusers to maximise pressure efficiency
- Frequency converters enabling variable speed control
- One converter controls four fans per sector
- External MCB-107 option card ensures control continuity during power unit failures
The retrofit proceeded tunnel by tunnel to minimise production impact. Testing verified cooling performance before returning each tunnel to operation.
↓ Service
Less frequent service than original equipment✓ Parts
Standard replacement parts ensure availability📅 Planning
Predictable schedules support production planningImproved operational resilience
The new fan systems deliver reliable cooling performance supporting 24/7 production. Variable speed control enables precise temperature management, maintaining consistent conditions for different product types.
This operational resilience protects production continuity and reduces downtime through improved reliability. The redundant control system maintains operation during component failures.
Improved operational resilience
The new fan systems deliver reliable cooling performance supporting 24/7 production. Variable speed control enables precise temperature management, maintaining consistent conditions for different product types.
This operational resilience protects production continuity and reduces downtime through improved reliability. The redundant control system maintains operation during component failures.
Energy savings deliver rapid ROI
The retrofit achieved 66% energy reduction, saving over 1.5 million kWh annually across the five tunnels. Operating cost reductions delivered return on investment in under one year, making the business case compelling for similar food production facilities.
Variable speed control optimises energy use by matching fan output to actual cooling demand, reducing output during lower production periods.
Quieter operation modernises facility
The new fans operate at considerably lower noise levels than the original equipment, improving working conditions for production staff and maintenance personnel. The quieter performance reflects improved aerodynamic design and mechanical precision.
The retrofit demonstrates practical Industry 4.0 implementation. Control system integration with facility automation enables remote monitoring and data collection. Production managers can track cooling performance and energy consumption in real time.
This connectivity supports predictive maintenance strategies. Performance data helps identify potential issues before they cause failures, further improving operational reliability. The project avoided costly new construction by modernising existing infrastructure whilst preserving the substantial investment in the original cooling tunnel structure.
Results summary
- Consistent cooling performance supporting production continuity
- Reduced downtime through improved reliability
- Lower maintenance frequency and faster service procedures
- 66% energy reduction (1.5+ million kWh annually)
- ROI under one year
- Reduced operating costs through lower maintenance and energy
- Integration with modern control systems
- Improved working environment through noise reduction
- Future-ready infrastructure supporting Industry 4.0 operations
