Success Story
Increasing Efficiency at an Australian Food Manufacturing Plant with Dimpleflo Heat Exchangers
Simplot Australia
Simplot Australia is a leading food manufacturer and the home of some of the most beloved Australian food brands. Their Ulverstone Potato Processing Facility, located near the Leven River, employs over 400 people and processes more than 250,000 tons of potatoes annually, producing 150,000 tons of frozen French fries.
Problem
Aging Plant Parts and Downtime Concerns
In 2021, Simplot’s plant was facing aging infrastructure and was due for a critical equipment upgrade. However, one major concern was minimising downtime—the plant could not afford extended shutdowns. The challenge was to replace the equipment while maintaining production efficiency and keeping shutdown time to an absolute minimum.
Solution Provided
Modern Technology and Optimised Design
Key Solutions
3D Scanning for Precise Replacement
Teralba used high-tech 3D scanning equipment to create a detailed 3D model of the existing unit. This allowed the team to accurately capture and document all critical components, including the support frame, steam connections, and the condensate return vessel. The new design offered improved performance while maintaining the same footprint to minimize installation complexity.
Dimpleflo Tubes for Increased Efficiency
The introduction of Dimpleflo tubes was a game-changer, significantly improving the heat exchanger's performance by creating turbulence that enhances heat transfer efficiency. By replacing the old plain tube design, the team achieved a significant boost in efficiency, optimizing flow patterns and steam distribution for even better results.
Implementation
Seamless Installation
The new Dimpleflo unit was designed to fit perfectly in the existing space, utilizing the same mounting points and connections as the old equipment. Pre-insulated and ready to go, the unit arrived on time, and the installation process went smoothly thanks to thorough planning and risk assessment by the Teralba team.
Efficient Delivery and Local Manufacturing
In a time of global shipping delays and supply chain disruptions, Teralba delivered the Australian-made equipment ahead of schedule, helping Simplot avoid international shipment risks. This was a huge win for Simplot, ensuring the project timeline stayed on track.
Results
17% Better Performance
The upgraded Dimpleflo heat exchanger improved performance by 17%, allowing Simplot to meet its production goals without expanding the plant’s footprint.
Smooth Installation
The installation was executed without delays, and the new equipment integrated seamlessly into the existing infrastructure, reducing downtime and allowing the plant to return to full production quickly.
Early Delivery and Support
The heat exchange unit, along with the steam condensate vessel and valve gear, was delivered early and ready for commissioning. Teralba also provided on-site support on the go-live day, ensuring that commissioning went smoothly without any setbacks.
Conclusion
The collaboration between Simplot Australia and Teralba led to a highly successful outcome. The Dimpleflo heat exchanger provided better performance, reduced downtime, and improved overall efficiency. By choosing an Australian-made solution, Simplot avoided global supply chain issues and received their equipment ahead of schedule, securing a fast and smooth installation process.
Explore Other Success Stories with Dimpleflo™
Vegetable Oil Processor Saves Costs with Dimpleflo Heat Exchangers
Success Story Vegetable Oil Processor Saves Costs with Dimpleflo Heat Exchangers Client Overview A vegetable oil processing facility located in...
Read More
Sydney Linen Cleaning Company Saves Big with Dimpleflo
Success Story Sydney Linen Cleaning Company Saves Big with Dimpleflo Client Overview A Sydney-based linen cleaning company processes 45 tonnes...
Read MoreReady to Transform Your Operations?
Let Dimpleflo™ help you optimise your heat transfer processes for increased efficiency, cost savings, and superior performance.