Hessing Greenport Venlo
In mid-2018, Hessing Supervers started the initial development of a new production site. The choice of location fell on Greenport Venlo finally. Construction started on March 31, 2021, and by the end of 2022 the first vegetable lines were moved to the new factory and production started. As of early 2023, the factory will be operational.
The factory was realized on a 100,000 m² plot, with a first floor area of 46,000 m² and two upper floors totaling 17,500 m².
Through automated processes, the new production site will soon process 320,000 pounds of vegetables into more than 850 different vegetable products every day, including ready-to-eat vegetables, processed fruits and meal salads. These will be delivered to supermarkets, fast food chains, wholesalers, catering companies and inflight caterers.
There will be 100 production lines for cutting, washing, drying and packaging fresh vegetables.
Most sustainable Vegetable Fresh factory in Europe
The new factory is the most sustainable Vegetable Fresh Factory in Europe. For example, the building meets the latest sustainability standards and the energy released when cooling the products is used to heat the offices.
Hessing Greenport Venlo thus scores “Very good” on the BREEAM sustainability ladder.
VHI Koudetechniek B.V. has realized the complete cooling and air conditioning of the production section, as well as heat recovery from the cooling installation for process water and heating the offices.
The production section, which consists of various separate sections and hygiene zones, is completely cooled at a temperature between 2 and 4 degrees Celsius.
Central cooling system
Het centrale koelsysteem is vanwege bedrijfszekerheid in twee circuits opgesplitst.
- Climate level (IT)
Cooling capacity 2x 1,600 kW at -3/+0°C providing pre-cooling of ice water and cold to the air conditioning systems (air handling and HVAC). Each cooling system equipped with 2 ammonia compressors. - Cooling level (MT)
Cooling capacity 2x 1,800 kW cooling capacity at -10/-7°C providing cold to all cold rooms and ice water systems. Each refrigeration system equipped with 2 ammonia compressors. - Freezing level (LT)
Capacity 48 kW at -30°C evaporation , with heat release at cooling level.
Heat pumps (HT)
There is a daily hot water requirement. In addition, heat is required for heating and drying various rooms. Two heat pumps are provided for this purpose, each with a capacity of 554 kW. The remaining heat comes from compressed gases, supplemented by condensation heat and heat recovery from the compressed air installation.
Buffer tanks for potable water, cleaning water and central heating are provided in the WT technology room
Ice water system
Outside next to the technology room, two ice silos were installed by VHI Koudetechniek B.V. with a diameter of 4000mm and 19 meters high.
These ice silos are each capable of cold storage of 6400 kWh (69 tons of ice). At the top, flake ice is produced by means of 3 falling film coolers per silo. The flake ice serves as a cold buffer for the irregular intake of cold ice water for the various washing and cutting lines in the plant.
To prepare the ice water, cold tap water is first pre-cooled, then buffered and post-cooled in two ice water silos.
Water chillers HVAC
For the cooling of offices, canteen and TD, a chilled water system was assumed. Via 12 plate exchangers of 50 kW each, chilled water of +6°C is produced by evaporating CO2 at +1°C. The WT installer connected the HVAC installation to this system.
Air treatment production
For the purpose of air filtration and renewal in the production area, 18 units of air handling units à 10,000 m3/h were installed and 16 units of extraction units à 10,000 m3/h were installed above the technical ceilings.
Air coolers
A total of 242 air coolers were installed to cool the production area.
The biggest challenge of this project has been planning. Due in part to changes during construction, immediate and rapid action had to be taken. In addition, the COVID-19 period, among others, made deliveries of required materials problematic.
Nevertheless, we were able to execute commissioning on time.