Animal Feed Cooler Replacement: Case Study

Problem

A manufacturer in the animal feed and cereal milling industry was dealing with a cooler system that had been in operation for 25 to 30 years. This equipment was not only outdated but also unreliable and noisy, which led to complaints from nearby businesses. The project called for a complete overhaul to modernize operations, cut down on noise, and ensure a future-proof solution—all while adhering to a tight timeline.

Impact

The aging cooler posed both operational and reputational challenges:

• Operational risk: The outdated equipment raised the chances of breakdowns, inefficiencies, and possible production halts.
• Community impact: The excessive noise resulted in complaints from neighbors, jeopardizing local relationships.
• Project complexity: The replacement process required structural reinforcement, floor replacement, mechanical installation, handling equipment, and the craning of heavy machinery—all of which needed careful planning to fit within a five-week shutdown period.

Solution

GAME Engineering carried out a complete cooler replacement, seamlessly integrating customer-supplied equipment with their in-house engineering know-how:

• Customer-supplied equipment: This included the cooler, pellet press, sieve, crumbler, fan, and cyclofilter.
• GAME-supplied equipment and services: They provided chain conveyors, discharge screws, supporting steelwork, custom aspiration ducting, access platforms, and chutework.
• Structural works: They fabricated steel in-house, CE marked to Execution Class 2 for load-bearing structures, and added extra steel to reinforce the cooler floor.
• Mechanical works: A dedicated team of eight engineers worked both weekdays and weekends, totaling 2,500 hours to complete the job.
• Craning operations: The pellet press was lifted through the roof under the watchful eye of a GAME-appointed lift supervisor, with trained signallers and slingers ensuring safety.
• Shutdown coordination: The entire Line 4 was shut down for about five weeks, during which the customer handled electrical and control software tasks.

The project successfully rolled out a cooler system that’s not only modern and quieter but also built to last. We made structural reinforcements and replaced the flooring to boost durability, while our in-house team handled the mechanical work to ensure everything was done safely, efficiently, and on time.

For more details, feel free to reach out to Game Engineering