Technical analysis and energy optimization of industrial refrigeration systems in food processing applications

This thesis, developed in collaboration with Pastificio Rana S.p.A., focuses on the analysis and optimization of industrial refrigeration systems and the thermal efficiency of production facilities, with particular emphasis on pasteurization and cooling processes. The study addresses the growing challenges associated with seasonal temperature variations, which strongly influence the performance of refrigeration units and the overall energy consumption of the plant. The research combines experimental thermal analyses, data collected from process sensors, and theoretical modeling to assess the current efficiency of the system and to identify the main sources of heat loss. The investigation highlighted several critical issues, including degradation of the pasteurizer insulation and the presence of direct steam leaks. Using thermal imaging, convection and radiation are calculated, and from these the energy balances are derived. It was estimated that the system currently dissipates 180,000 kWh per year of thermal energy into the surrounding environment. Based on these findings, several corrective actions were proposed, such as replacing damaged insulation panels, performing maintenance on the pasteurizer steam lines, and installing solar-control window films in office areas to reduce cooling demand. These interventions are expected to significantly improve both energy efficiency and operational stability. Overall, this work demonstrates how a detailed thermodynamic analysis combined with targeted maintenance strategies can lead to tangible energy and economic benefits in industrial food processing facilities.