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Plate Cooler

alternative practice names:

Precooler; Well Water Plate Cooler; Well Water Precooler; Plate Heat Exchanger

Plate coolers, also known as precoolers, are heat exchangers that pre-cool milk before it is cooled to its final temperature in the bulk tank. The most common type of plate cooler uses a series of stainless-steel plates that utilize either well water or glycol as a coolant that flows through the plate cooler in one direction and absorbs heat from milk passing through the plate cooler in the other direction. 


The most energy-efficient type of plate cooler uses well water as a coolant, which has a relatively stable temperature throughout the year. Groundwater temperatures range from around 40-75°F depending on the location, and essentially act as a constant geothermal energy source. A properly sized plate cooler can cool milk to within 12°F of the groundwater temperature, which can reduce milk cooling energy requirements by 30-60%. 


Plate coolers result in even greater energy savings when paired with a milk transfer pump variable frequency drive, which pumps milk through the plate cooler at a steady rate and improves heat transfer, cooling milk to within 4-5°F of the groundwater temperature before it enters the bulk tank.

When used, in what regions in the U.S. is the practice found: 

Northwest, West, Upper Midwest, Southwest, Northeast, Southeast

FARM SIZE 

When used, typically found on farms of the following sizes:

All Sizes

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Practice Benefits 

Improved profitability: The main benefit of installing a plate cooler is to improve profitability by reducing the amount of electricity used to cool milk, particularly if well water is used. Since plate cooler pre-cool milk before it enters the bulk tank, they also extend the life of the bulk tank refrigeration system.


Improved milk quality: Plate coolers can improve milk quality by cooling it more quickly and reducing potential for bacterial growth. 


Increased water use efficiency: Warm water exiting a well water plate cooler can be provided to cows as drinking water, or used for other water needs on the farm.

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Implementation Insights

Site-specific or Farm-specific requirements 

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  • Operational considerations: The energy savings potential of a plate cooler varies depending on the temperature of groundwater and the size of the plate cooler. In areas where the groundwater temperature is too high, it may be more economical to use a glycol plate cooler. Additionally, because plate coolers transfer heat from milk into water before it enters the bulk tank, they reduce the energy savings potential of compressor heat recovery units that utilize waste heat from the bulk tank refrigeration system to pre-heat water for cleaning. For dairy farms considering both practices, it is recommended to get input from a dairy farm energy auditor or equipment vendor experienced with plate coolers and compressor heat recovery systems to determine the most energy-efficient configuration.

Required Capital Expenditures (CapEx)

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  • Plate cooler: The primary expense is the plate cooler itself, along with the labor required to install it. The design of the system should be completed by the equipment vendor and will be included in the cost. There are no special electric requirements needed for a well water plate cooler. 

  • Milk pump variable frequency drive (VFD): When installing a plate cooler, it is always a good idea to consider installing a milk pump VFD as well to maximize the energy use reduction potential. While it presents additional up-front expenditures, a milk pump VFD typically pays back quickly.

Required Operational Expenditures (OpEx)

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  • Maintenance: Ongoing maintenance costs for plate coolers are generally low, and maintenance can be performed in-house without skilled labor. It is typically recommended to open the plate cooler every few months to clean the plate surfaces with a plastic brush to prevent buildup and ensure that heat exchange remains optimal. The plates do not need to be removed, and the equipment can be cleaned in place. It is best to follow the maintenance instructions provided with the plate cooler since maintenance procedures vary by make and model. Any maintenance costs should be greatly outweighed by the energy cost savings provided by the plate cooler.

Implementation Considerations

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  • Installation location: Plate coolers should be installed after the milk filter in a location that is easy to access for maintenance, and close to water and milk line connections. They are typically installed using a bracket to mount the unit to the wall. 

  • Operational compatibility: Plate coolers should be sized based on the volume of milk being produced at the farm and the flow rate of water and milk in the plate cooler should be the same—typically a one-to-one ratio—to ensure maximum energy savings potential. 

  • Water source: If well water is being used as the coolant, is important to ensure that the well can supply water at the required flow rate needed to supply the plate cooler.  

Financial Considerations and Revenue Streams

FEDERAL COST-SHARE AND CONSERVATION FUNDING

Funding is available for this practice through USDA's Natural Resources Conservation Service (NRCS) Environmental Quality Incentives Program (EQIP) On-Farm Energy Initiative.

Notes:

  • An Agricultural Energy Management Plan (AgEMP), or other qualifying energy audit, needs to be completed before applying for EQIP assistance.

  • Check with the local NRCS office on payment rates and practice requirements relevant to your location.


The USDA Rural Development Rural Energy for America Program (REAP) also offers competitive grants and loan guarantees for installing energy efficiency projects.


OTHER CONSERVATION FUNDING

Plate cooler rebates are sometimes available through the farm’s electric utility company.  

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Environmental Impacts

REDUCES FARM GREENHOUSE GAS FOOTPRINT

Improving energy use efficiency reduces a farm's greenhouse gas (GHG) footprint. Since energy production typically involves processes that emit greenhouse gases like carbon dioxide and methane, cutting energy use directly lowers the GHG footprint of the farm.

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Alignment with FARM Program

FARM Environmental Stewardship (ES) V2-V3 Alignment

FARM ES captures a farm's energy usage and calculates the associated GHG emissions based on regional energy production and transmission averages. Any practice that reduces farm energy consumption will directly lower the farm's GHG footprint. The reduction in GHG emissions is particularly pronounced in regions where a larger proportion of energy is derived from coal, natural gas, or other fossil fuel sources, as these energy types have higher carbon footprints compared to renewable energy sources.

Contents

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We're always eager to update the website with the latest research, implementation insights, financial case studies, and emerging practices. Use the link above to share your insights. 

We're always eager to update the website with the latest research, implementation insights, financial case studies, and emerging practices. Use the link above to share your insights. 

Contents

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Practice Overview

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Research Results.png
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Plate coolers, also known as precoolers, are heat exchangers that pre-cool milk before it is cooled to its final temperature in the bulk tank. The most common type of plate cooler uses a series of stainless-steel plates that utilize either well water or glycol as a coolant that flows through the plate cooler in one direction and absorbs heat from milk passing through the plate cooler in the other direction. 


The most energy-efficient type of plate cooler uses well water as a coolant, which has a relatively stable temperature throughout the year. Groundwater temperatures range from around 40-75°F depending on the location, and essentially act as a constant geothermal energy source. A properly sized plate cooler can cool milk to within 12°F of the groundwater temperature, which can reduce milk cooling energy requirements by 30-60%. 


Plate coolers result in even greater energy savings when paired with a milk transfer pump variable frequency drive, which pumps milk through the plate cooler at a steady rate and improves heat transfer, cooling milk to within 4-5°F of the groundwater temperature before it enters the bulk tank.

Practices and technologies

Plate Cooler

alternative practice name:

Precooler; Well Water Plate Cooler; Well Water Precooler; Plate Heat Exchanger