In 2019, we installed a flake ice plant at a Scottish salmon processing company. As our customer continues to expand their business, there was a need for more ice to pack the salmon. The limited space in the existing building once again highlighted the benefits of our container solution when we installed a flake ice plant next to the building with a production capacity of 80 tons per day.

Our turnkey installation includes a plant for the production of 80 tons of ice per day with an automatic ice storage with a capacity of 40 tons. A substructure, stairs and platforms, and an ice conveyor system complete the installation along with smaller accessories. We started the construction at the end of July 2019 and the whole setup was fully commissioned after only about 6 weeks.

Flake ice production takes place on ice makers with chrome-plated surfaces. The refrigeration circuit is air-cooled and an economizer together with the use of NH3 / ammonia as refrigerant leads to highest energy efficiency.

Ice is stored in a stainless steel tank with our reliable air circulation channels to keep the internal temperature below freezing and ensure optimal storage of flake ice. An automatic ice rake constantly levels the ice and discharges it when needed.

The ice transport system then delivers the ice to several ice feeders, which weigh it and pack it together with the fresh salmon in insulated boxes ready for shipment. Alternatively, our customer also uses the flake ice to produce so-called slurry ice.

A Belgian producer of dyes and pigments was able to further automate its production processes. KTI's solution for the production of flake ice has supported this. In particular, as ice conveying and distribution could be automated and connected to the central control system. Another highlight is the heatmer recovery. 

A Belgian manufacturer of pigments and dyes received a solution from us for the production, storage, and conveying of flake ice. In addition to the actual ice production, automation and energy efficiency were also important aspects in the selection of the KTI systems.

A flake ice plant was installed which, in addition to ammonia as the most efficient refrigerant, also has integrated heat recovery. As a result, the combined efficiency ratio (COP) is extremely high. The equipment heats water during ice production, which is used for cleaning in the production process. Likewise, a water pre-cooler was installed to bring the water to an optimal temperature for the actual ice production.

In addition to an ice storage system, two pneumatic conveyors were also installed. These are equipped with compressed air coolers. The ice is thus dosed into the already cooler air via a rotary valve before it is then transported further to its destination.

The entire unit is automated and integrated into our customers' central control system. Thus, the production processes could be optimized.

Two KTI ice plants, including ice storage and pneumatic ice conveying, were commissioned at a leading German chemical producer. The old existing plant was replaced. The quality of the final product was further improved by increased process stability.

Back in 2013, KTI was able to help a large chemical producer with a temporary solution for the production and storage of ice. As the old plant failed, a remedy had to be found quickly. Due to the containerized design of KTI ice plants, KTI ice storage and other accessories, ice production could be set up immediately on site and the process could be supplied with flake ice.

Our customer was so enthusiastic that a new ice cream production facility was built at the site the following year. Only KTI solutions were used here, which are perfectly coordinated with each other and thus offer a high degree of process reliability. Redundancy was also taken into account in order to increase production capacities at short notice but also to bridge maintenance periods.

The installed ice conveyor was equipped with air coolers and a weighing system. An "ice switch" was also installed. Our customer can thus choose between different lines for ice transport - depending on which reactor requires ice. With the integration into the central control system, full automation could be achieved.

Once again, we at KTI had the pleasure of supplying two liquid chillers to the largest beverage manufacturer in Dubai. Due to the adaptation to the customer's needs, our customer saves cash due to the increased energy efficiency. In addition to two units, we supplied a pump station to supply cooling water to the consumers.

Also in 2022, we installed two liquid chillers at the largest bottler of drinking water. The two units were used to expand our customer's production capacities. As both were installed in containers, the construction work could take place in parallel and costs were already optimized during the expansion.

Due to the energy efficiency of the equipment, we were able to offer our customer real added value, as our cooling systems were optimized for the hot weather conditions, especially during the summer.

A system is used to cool the stretch blow molding machines and other processes. Since the consumption or the need for cooling can vary greatly, we have supplied a pump station that reliably supplies the consumers. A stepless power control has also been integrated.

The other equipment is used to pre-cool the drinking water. Before it is filled into the containers, it must be brought to the optimum temperature to ensure freshness and the best taste.

In a Brazilian gold mine, we installed an underground ventilation system, our Underground Chiller UC 500, with a cooling capacity of up to 600 kWR. The mine urgently needed spot cooling to deepen the shaft for further exploration. Since our underground chillers are specifically designed for the adverse conditions and can be easily moved through the mine, installation and commissioning was quick. The mine now meets its safety requirements for safe working.

In 2021, we were approached by our customer when an urgent need for underground cooling arose in the course of shaft deepening. In cooperation with a partner company that is a global leader in mine ventilation, we were able to develop a cooling concept on site. Our Underground Chiller was integrated into the cooling concept as it offers several advantages compared to conventional water coolers.

A crucial requirement was the high corrosion potential due to the acids and minerals contained in the groundwater. Due to the special design and material selection of the heat exchangers, the Underground Chiller was able to cope with this without any problems. In addition, the service life is much longer as a result. The entire unit was lowered upright through the shaft and then simply moved underground to where it was needed. This met a second requirement and avoided the need to build special ramps.

After placing and connecting the chiller to water, power and cooling car, our trained technicians successfully commissioned the chiller. Several tests were carried out and the performance record of the Underground Chiller was established to the full satisfaction of all parties involved

Between 2013 and 2017, we installed several slab ice plants and chilled water plants for our customer's operations, providing a total of 1680 tons of slab ice per day. This corresponds to around 3 MW of chilled water at 3 °C. We prefabricated the plants in Germany and were thus able to reduce installation and commissioning costs enormously. A heat load of 15MW at a depth of 2,500m requires 25,000 tons of water at 5°C, but only 3,200 tons of ice. This leads to enormous savings in pumping energy, since the heated water would have to return to the surface.

In 2013, our customer, a South African gold mine, approached us to expand its cooling systems. In total, this would need about 2000 tons of ice in the next few years. The ice would be produced on the surface of the mine. However, such a large cooling system requires an enormous investment. Together with other advantages associated with containerized, modular systems, we were able to help the customer take an approach that spreads the investment over several years.

Thus, in 2013, we delivered two plate ice plants, Ice Crusher and Ice Discharge System to the customer with a total production of 440 tons of ice per day. A short delivery time of our plants quickly covered the demand for cooling compared to only one large-scale plant.

In a second and third phase, the plant grew with the customer's cooling needs, as did the mine. We supplied more modules until the plant reached full size in 2017, with a total production capacity of 1680 tons of ice per day.

Two water pre-coolers were also installed to supply the ice plants with water at a temperature of 5°C. This is economical and energy-efficient. This is economical and energy-efficient.

KTI snowPRO systems have always been used for snowmaking in freestyle competitions. Even for the world's top athletes, the snow quality of our systems is convincing. That is why the freestyle event in Chur took place again in October 2022.

Together with the company snowbox GmbH we have from KTI snowPRO to success at the FIS Freestyle World Cup for men and women in Chur. A facility of the type snowPRO70 produces about 70 m³ of snow per day to cover the ramp with snow. Despite adverse weather with warm winds and rain, the event has become a great success.

The athletes as well as those responsible for the preparation of the ramp were enthusiastic about the result and the event could be held without any problems.

Back in 2014, we introduced the very first snowPRO systems in Zurich for snow production at a similar event. This confirmed the path for the technology and its use in the event sector even then.

Snow uncertainty is a critical factor for winter tourism. With the KTI snowPRO technology, we have created new opportunities for a ski resort in Sauerland, Germany, in that the season can now be planned and snow is guaranteed. In addition to the first installation in 2014, seven other lifts followed in the region, which were equipped with the technology from KTI snowPRO are equipped. 

Already in 2014 we are equipping from KTI snowPRO a region in the Sauerland region with a system for snowmaking at plus degrees. The uncertain weather and fluctuating temperatures played an increasingly important role in the issue of snow reliability when it came to planning the opening of the ski area. Due to its location, the popular ski resort attracts German winter sports enthusiasts but also English, Dutch and Danish skiers.

Four years later, in 2018, followed another installation of two turbines of type snowPRO210 and already in 2019 another two of the same design. With a total of six systems, the winter sports resort can now speak of real snow reliability. All of the installed systems generate flake ice, which is transformed into snow by a mechanical process.

In 2020, the first plant of the type snowPRO260 installed. With plate ice as a real alternative to flake ice, the success story of this technology, which is extremely energy-efficient and effective for snowmaking at plus degrees, begins here. In 2022, another of the same type followed in order to continue to guarantee snow reliability for winter sports enthusiasts and to ensure plannability for the important economic sector of tourism.

The installation of a KTI snowPRO on the Titlis glacier in Engelberg presented us with some challenges. On the one hand, the transport from the valley up to the summit as well as the actual installation height of 3020 meters were the crucial points that we were able to master successfully.

In 2018, we installed from KTI snowPRO a glacier snowmaking facility on the Titlisgeltscher glacier in Engelberg. The facility will provide year-round snowmaking and thus snow fun for all visitors from all over the world. The snow produced will also be used to repair cracks and renew dirty snow. Snow melting due to excessive sunshine can thus be counteracted.

A key challenge was the execution of the installation of the equipment. KTI snowPRO is the only manufacturer of comparable equipment that has its own development and production of equipment for snowmaking at positive temperatures. Only this allowed us to work out a solution that offers a perfect solution to the customer's problem:

A certain maximum weight was prescribed for the transport. We therefore used the classic snowPRO100 divided into matching modules. Each of the modules was then transported separately up the mountain and easily reassembled at the top. A solution was also found for the complex installation situation. Instead of a classic 40-foot container, two 20-foot containers were used and the plant components fitted in accordingly.

In 2019, we replaced an old existing plant in the port of La Reunion with a modern ice production facility. To reliably supply local fisheries with flake ice, our FLIP (Flake Ice Plant) produces 15 tons per day. The plant is operated - similar to a gas station - by the customer himself.

Already in the fall of 2018, we received an order from our customer to develop a new, modern ice production for the port on La Reunion. In addition to the ice production itself, which meets the latest technical standards, storage, transport and weighing were also required.

The ice production plant was designed with ammonia (R717) as refrigerant. This ensures high energy efficiency. Likewise, no damage to the environment and climate is to be expected in the event of a leakage, which is important to both our customer and us. The produced ice is stored in an ice warehouse with a room temperature between -5°C / 23°F and -7°C / 19°F to keep the flake ice storable.

Our customer has chosen a batch weighing system for ice, which is designed for a weight of up to 450 kg / 990 lbs per weighing. The desired weight is set via a terminal PC, which is installed in a separate compartment from the technology. Access to it is realized via a chip-card system. The chip cards also serve to authenticate the ice cream customer for the integrated billing system.

Once the ice has been weighed, it is transferred directly to the docking ship via a pneumatic transport system. A flexible hose can simply be placed on the spot.

In February 2018, a Danish logistics company for fish approached us with the challenge of designing a plant that would meet their specific needs while at the same time fulfilling the highly demanding hygiene standards. This essentially involved a flake ice production of 100 tons of ice per day and an ice storage with a capacity of 90 tons. Furthermore, the ice has to be conveyed into the hall over a distance of 36 meters.

The flake ice plant was too large to be accommodated in the factory. Therefore, we installed the machines in standard shipping containers. This approach made it possible to place the ice machine, which can produce 100 tons per day, and the associated 90-ton ice storage system with our proven ice rake system next to the outer wall of the factory. At the same time, we planned to convey ice over a distance of almost 40 meters from the ice production unit to four ice batching units. Each ice feeder can only hold about 150 kg of ice at a time, and every meter of distance reduces the flexibility of supply. We realized this with an optimized control of the ice discharge system.

Another challenge was the design of the machines themselves, as the ice must be hygienically spotless at all times. This meant leaving as few hard-to-clean corners and gaps as possible. The antibacterial properties of the stainless steel and its high resistance to cleaning agents virtually rule out contamination of the ice while also making it easier to clean the components.

As refrigerant for ice production we used ammonia (NH3), which is ecologically unproblematic and basically available in unlimited quantities. In combination with a so-called economizer and a water pre-cooler, we increased the energy efficiency by approx. 10% compared to similar plants.

The plant has already been commissioned in Q3 2018 and fine tuning and interfaces with the fish processing plant have been established.

After we delivered our solutions for the production of mass concrete in winter to our customer in Patagonia in the extreme south of Argentina at the beginning of 2020, the delivery of a solution for concrete cooling followed towards the end of the year. The construction of a hydropower plant there requires the highest demands on the temperature of the mass concrete, as extreme ambient temperatures prevail and the durability of the concrete must be ensured.

Not for the first time, we were able to convince the customer with our competence and the wide product range of concrete heating and cooling equipment. From a single source, we supplied and commissioned our equipment for year-round concrete production. In order to avoid thermal stress, cracking and unwanted shrinkage, a rule of thumb states that the fresh concrete temperature to be achieved should be equal to the annual average ambient temperature. In this project, the fresh concrete temperature was defined as 10 °C / 50 °F, while the ambient temperature reached 30 °C / 86 °F in summer and was below 10 °C / 50 °F in winter. The total daily production capacity was set at 3,000 m³ of concrete per day.

To ensure the required concrete temperature, we supplied a complete solution for concrete tempering consisting of the following components and providing a heating capacity of approx. 4000 kW and a cooling capacity of approx. 1300 kW.