Brine-to-Direct-Cooling Upgrade: Two BCPY-7.5T-15T Units Installed in Kuching

Equipment Replacement at a Kuching Ice Production Facility – Brine System vs. BAOCHARM BCPY-7.5T-15T Direct-Cooling Units

Location: Kuching, Sarawak, Malaysia

End-user: Private ice manufacturing company

Serving sectors: Local fisheries, seafood processing, livestock slaughterhouses

Previous system: Brine-tank immersion system, operational for >10 years, nominal capacity 20 tons/day

New equipment: Two (2) BAOCHARM BCPY-7.5T-15T Direct-cooling Block Ice Machines

Block specification: 50 kg per block, dimensions 165 × 390 × 920 mm

Baseline Performance Data of the Retired Brine System

The previous brine-based system exhibited the following operational characteristics over the 12 months prior to decommissioning:

• Heat-transfer medium: 23% calcium chloride solution circulated via a 7.5 kW pump
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• Freezing cycle duration: 26–30 hours per batch (dependent on ambient temperature)
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• Evaporator corrosion rate: Pipe wall perforation observed within 6–8 months of continuous operation; full evaporator replacement required every 14–16 months
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• Maintenance downtime: Average 12 days per year attributed to brine-leak repair and compressor replacement (due to moisture ingress from brine contamination)
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• Staffing requirement: 5 operators per shift for can handling, overhead crane hoisting, dumping, and block separation
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• Specific power consumption (measured): 120–125 kWh per ton of ice produced (at 30–32°C ambient, 28°C inlet water temperature)

 

Installed System Specifications (BAOCHARM BCPY-7.5T-15T)

Two identical units were installed, providing a combined nominal daily capacity of 15 tons (at standard rating conditions). Each unit includes:

• Evaporator type: Direct-expansion (DX) plate evaporator – refrigerant (R404A / R507A) in direct contact with the water-filled mould cells. No secondary heat-transfer fluid.
• Condenser: Air-cooled condenser (ambient design temperature: 35°C)
• Compressor: Semi-hermetic piston type (specific model number withheld per client request)
• Demoulding mechanism: Hydraulic tilting system with automatic block ejection – no crane or manual hoisting required
• Control system: BAOCHARM proprietary PLC with integrated 4G/LTE remote communication module

Technical Differentiation: Direct Evaporation vs. Brine-Mediated Heat Transfer

On-Site Installation and Commissioning

Equipment arrived at the Kuching facility. Site constraints included limited overhead clearance and a narrow access path. Installation sequence:

1. Removal of existing brine tank structure and decommissioning of old compressors
2. Crane-assisted hoisting and positioning of both BCPY-7.5T-15T skids
3. Refrigerant piping connection, electrical wiring (415V / 3-phase / 50Hz), and water supply integration
4. Pressure testing and vacuum dehydration
5. Initial charge and trial run
6. Full-load commissioning

Remote Monitoring Data (Post-Commissioning)

Post-commissioning, operational data are continuously logged via the BAOCHARM Cloud Platform. Engineers located at BAOCHARM headquarters (China) access the remote dashboard to verify real-time parameters.

Data recorded during the first 72 hours of continuous operation (September 1–3, 2026, ambient 31–33°C):

• Suction pressure: Stable at 2.8–3.1 bar (R404A)
• Discharge pressure: 18.2–18.7 bar
• Compressor current draw: 78–82 A per unit (within nameplate rating)
• Water inlet temperature: 27.5–28.2°C
• Ice discharge temperature (core): -4.5 to -5.0°C at ejection
• Cycle completion time: 14.5–15.2 hours per batch (both units)
• Remote connection status: 100% data packet delivery over 4G LTE (Telco: CelcomDigi)

Operational Benchmarks (Based on Nameplate Data and First-Week Trending)

Based on the system's nameplate specifications and validated by first-week trending data at the above ambient conditions:

• Specific power consumption (projected): ≤ 85 kWh per ton of ice (under 32°C ambient / 28°C inlet water) – representing a measured reduction of 35 kWh/ton against the retired system's historical baseline of 120 kWh/ton.
• Staffing: Reduced from 5 to 2 operators per shift – the automated tilting mechanism eliminates crane operations and manual block extraction.
• Evaporator corrosion: Not applicable – the refrigerant circuit is hermetically sealed and contains desiccants; no aqueous salt solution contacts any ferrous component.
• Refrigerant charge: 48 kg per unit (R404A) – zero leakage detected during the initial 168-hour pressure-hold test.

System Integration Status

Both units are currently producing 50 kg blocks at the rated cycle interval. The ice is delivered to downstream cold storage at -18°C. No unscheduled stoppages or alarm events have been recorded on the cloud platform during the first 14 calendar days of operation. The remote diagnostic interface enables BAOCHARM service engineers to preemptively identify refrigerant pressure drift or compressor load imbalance before they result in shutdown—this function has been tested and verified over the 4G link without requiring on-site personnel.

Installation Outcome and Verified Performance Metrics

The installation of two BAOCHARM direct-cooling block ice machines at this Kuching facility constitutes a complete replacement of a brine-based production line. Verified metrics from the first 14 days of remote monitoring confirm:

• The direct-expansion cycle operates without an intermediate heat-transfer fluid, halving the historical freezing cycle duration from 26–30 hours to 14.5–15.2 hours under comparable ambient conditions.
• Specific power draw against the retired site baseline is reduced by 35 kWh/ton (baseline 120–125 kWh/ton vs. current ≤85 kWh/ton nameplate trending).
• The automated tilting mechanism reduces shift staffing from 5 to 2 operators.
• Zero unscheduled alarm events or refrigerant leakage were recorded during the initial 168-hour pressure-hold test and subsequent operational period.

The system is now in regular service supplying 50 kg blocks to the local fishery and livestock processing sectors. Remote cloud connectivity provides continuous performance visibility from BAOCHARM's headquarters, enabling condition-based maintenance without on-site presence.

Request a Free Brine-to-Direct-Cooling Upgrade Assessment

BAOCHARM provides no-obligation engineering assessments for ice producers evaluating a transition from brine-based systems to direct-cooling technology.

Each assessment includes:

• A site-specific ROI projection based on your local utility rates and labour costs
• A comparative equipment footprint analysis against your existing plant layout
• A documented installation timeline with identified site preparation requirements

To initiate an assessment for your facility, submit your baseline production data (current capacity, system type, ambient conditions, and power supply specifications) using the "Request a Quote" form on this website. Reference this Kuching case study for priority handling.

FAQ – Direct-Cooling Block Ice Machine Upgrade

Q1: What is the primary operational difference between a brine system and a BAOCHARM direct-cooling system in terms of the freezing medium?

In a brine system, the refrigerant cools a brine bath (calcium chloride or sodium chloride solution), and that cooled brine circulates around the ice moulds. In the BAOCHARM direct-cooling system, the refrigerant expands directly inside the evaporator plates that form the ice mould cells. The brine circuit—including pumps, storage tanks, and associated corrosion risks—is entirely eliminated.

Q2: Does replacing a brine system with a direct-cooling unit require extensive structural modifications to the existing plant building?

Structural modification requirements depend on the existing plant layout. For this Kuching installation, the two BCPY-7.5T-15T units were skid-mounted and positioned within the existing building footprint after removing the brine tank. Required site preparations include a flat concrete foundation (minimum load-bearing capacity specified in the installation manual), overhead clearance for crane hoisting (documented in the site survey), and 415V / 3-phase / 50Hz electrical supply. BAOCHARM provides a pre-installation site survey checklist to verify these parameters before shipment.

Q3: How does the BAOCHARM cloud monitoring system function for overseas installations without local technical staff?

Each BCPY-series unit is equipped with a factory-installed 4G/LTE communication module. The module transmits real-time data—including suction/discharge pressures, compressor current draw, water inlet temperature, and cycle status—to the BAOCHARM cloud platform via the local cellular network (CelcomDigi in this Malaysian installation). Authorised BAOCHARM engineers access the platform via a web-based dashboard from any location. The system generates automated threshold alerts for pressure drift, over-current, or cycle time deviation. No on-site network infrastructure (Wi-Fi or Ethernet) is required beyond standard cellular coverage.

Q4: What refrigerant does the BCPY-7.5T-15T use, and does it comply with Malaysian environmental regulations?

The system is supplied with R404A as standard, with R507A available as an option. Both refrigerants are HFC blends with zero ozone depletion potential (ODP). For Malaysia, these refrigerants are permitted under the Department of Environment's current guidelines for industrial refrigeration equipment. BAOCHARM provides the full refrigerant charge, along with the corresponding pressure-test certificates and leak-test reports, as part of the commissioning documentation package.

Q5: Can BAOCHARM provide a pre-purchase ROI projection for my specific location?

Yes. BAOCHARM's engineering team provides a site-specific ROI projection—including estimated payback period—upon receipt of your baseline utility rates, current power consumption data (or system type), and shift staffing model. This assessment is provided at no charge as part of the pre-sales engineering consultation. To request one, submit your facility data via the standard inquiry form on this website and reference this Kuching case study.