GEA supplies modern refrigeration technology for Europe’s most efficient cold store from Magnavale

GEA is going to supply a refrigeration system for the UK’s tallest cold store. Magnavale, one of the UK’s leading cold storage providers, is building a 47-meters high cold store with a capacity of 101,000 pallets in Easton Lincolnshire in the East of England. The facility will be fully automated and powered 100% by renewable energy. According to Magnavale, they aim to make it the most efficient cold store in Europe. The huge facility will be built next to an existing 44,000-pallet cold store, also owned by Magnavale, on the same site.

The cold storage facility will go into operation in the fourth quarter of 2024. GEA has already equipped numerous cold storage facilities worldwide with modern and energy-efficient refrigeration technology. As part of a framework agreement, GEA will supply refrigeration technology for other Magnavale high-bay warehouses being built in the future similar to the Easton project.

The new building will be used for cooling frozen food products. It is designed with the capability to reach minus 28 degrees Celsius, so it can be used for storing numerous products including fish and ice cream. The dimensions of the high-bay warehouse are 150 meters long by 100 meters wide and 47 meters high. The high bay coldstore interfaces with a 35 meters long expedition bay which has 20 loading docks. Itis also supplemented with two floors for value added services.

Individually tailored solution for Magnavale

Together with the customer, GEA developed an individually tailored solution for the new cold store. For example, GEA performed in-house computational fluid dynamics (CFD) simulations to illustrate the air flow and temperature profile within the high bay cold store based on the cold lake principle design. This helped demonstrate the effectiveness and superior efficiency of the GEA solution offered compared to a conventional cold store design.

The project was then implemented with a two-stage ammonia refrigeration plant from GEA with optimized circulation rate. The plant comprises of three screw compressors, three reciprocating compressors and three condensers. Furthermore, ten air coolers are installed in the high-bay cold store and 22 in the loading bay area. The GEA screw compressors are employed as the low stage booster compressors, coupled with GEA Grasso V-series reciprocating compressors to take advantage of the reciprocating compressors’ enhanced COP at part load operation. This design maximizes the cooling efficiency under all part and full load operations.

Background information: Magnavale

 Headquartered in Chesterfield, Magnavale is one of the UK’s largest specialists in temperature-controlled food storage and value-added services. For over 30 years, Magnavale has provided industry-leading cold storage and value-added solutions. Its cold storage facilities are strategically located in the UK, providing efficient access to the market. Magnavale’s existing coldstores in Warrington, Chesterfield, Scunthorpe, and Grantham.

As part of Magnavale’s ESG strategy and their path towards a net zero future, the company has made substantial technological upgrades to their existing network. Magnavale aim to be the greenest provider of temperature-controlled storage and added value services in the UK and combined with the development of their new store in Easton, Lincolnshire the improvement of their existing facilities puts Magnavale firmly on that path.