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Worldwide

Concrete Cooling
Systems
01.09.2012
The Company
How it all began ...
In 1923 Richard Plersch sen. began
with the design and manufacturing
of components and plants for the
refrigeration industry. His son Richard
Plersch II continued the tradition and
established the global reputation of
PLERSCH products.
Today, the company is run by Rupert
Plersch in the third generation. As
managing director he keeps the family
tradition and philosophy alive. In a well-
founded entrepreneurial spirit he has
established KTI-Plersch Kältetechnik
GmbH and in the last 25 years the
company has become a leading refrig-
eration contractor worldwide. PLERSCH
products stand for first-class, cutting
edge refrigeration plants of top quality
made in Germany. Since 1986 more
than 2,500 cooling plants have been
sold and installed worldwide. In addi-
tion to the production of turnkey solu-
tions for the concrete cooling industry,
the sale of components and spare
parts as well as service and consulta-
tion are KTI core business areas.
General Cooling Requirements
Qo = Δt · 0.69 kWh/m³ K
32 kWh/m³
Sand Cooling
(+25°C)
26.7 kWh/m³
Aggregate Cooling
(+10°C)
19 kWh/m³
Flake Ice
(- 7°C)
9 kWh/m³
Cold/Ice Water
... and where we are today KTI Facts & Milestones (+1°C)
KTI-Plersch Kältetechnik GmbH is a 1994 Opening of new production facili- 0.69 kWh/m³
dynamic and innovative German refrig- ties in Balzheim 11 K 25 K 35 K 42 K
eration contractor specializing in con- 2000 Cooperation and sales agency CIWP FLIP CACS-w/a SC
crete cooling and special equipment. contract with VIP Various Ice Δt
Products, Dubai, to manufacture
In the past 25 years KTI-Plersch
mobile ice storages Temperature-Controlled Concrete hydration raises the temperature during Although the required pouring tempera-
Kältetechnik GmbH has set new stan-
2002 Construction of new office the curing process by up to 25° causing tures of the concrete vary from site to
dards for block ice plants and flake ice Supplying temperature-controlled con-
buildings and assembly hall in an increase of volume. After the curing site and from country to country (from
plants as well as for fully automatic ice crete for any major construction site is
Balzheim the concrete cools down, again reduc- +7 °C to max. 30 °C) there is always a
storage and delivery systems. a must all over the world. The develop-
2003 Opening of additional assembly ing its volume and thus naturally requirement for a sophisticated refrig-
ment of the strength in concrete is
At company headquarters in Balzheim, hall and comprehensive staff causing cracks eventually. Therefore eration system.
accompanied by evolution of heat as
ice plants and cooling systems are facilities in Balzheim the initial pouring temperature should As the initial and the running costs for
the cement cures and hardens (heat of
developed, designed and manufactured 2006 KTI Qatar opens offices in Doha be lowered so much that the maximum such a refrigeration system are quite
hydration). In small structures this phe-
to meet the most diverse needs of KTI 2006 KTI Saudi Arabia establishes temperature during the curing process high (they even can be higher than the
nomenon is not of importance, but very
customers worldwide. offices in Dammam, Jeddah and does not exceed a certain temperature ones of the concrete batching plant
significant in mass concrete, for
Riyadh determined by the consultants. itself), it is essential for the contractor
KTI is a solution finder: the main goal instance for dam projects. The heat of
2007 Construction of additional to have an optimised system installed.
is to provide the very best solutions to
production facility in Balzheim
the concrete cooling industry. KTI cool-
2008 KTI-Plersch – Dubai Branch opens
ing solutions always consider customer
needs and requirements.
2010 KTI-Plersch do Brasil Concrete Mixing Temperature
(Sao Paulo) established as function of water temperature and addition of ice respectively
KTI means responsibility, know-how, 2010 KTI India opens offices
expertise, three generations of experi- 2010 Founding of Sauter Plersch AG
Dune sand Washed sand Aggregates 10mm Aggregates 20mm Cement Water
ence, innovation, team spirit, and deep 2012 Extension of office and produc- 230 kg/m3 665 kg/m3 230 kg/m3 690 kg/m3 380 kg/m3
personal commitment by the Plersch tion facility Balzheim 45 °C 45 °C 45 °C 45 °C 75 °C
family and the employees. We work 35 °C 35 °C 35 °C 35 °C 75 °C 170 kg/m3
KTI Agencies and Registered Offices
hand in hand. This approach has made 25 °C 25 °C 25 °C 25 °C 75 °C
us what we are today: In addition to its branches and offices, 1% moisture 2% moisture
KTI has agencies all over the world: Assumption of mix design for calculation
• A successful international company
Brazil (Sao Paulo), KTI do Brasil 50 °C 50 °C
• An innovative company with a
China (Beijing)
solution oriented service mentality Temp. before mixing 49 °C
Egypt (Cairo) + 170 l Ice Water 1 °C
• A customer-centered provider
India (Chennai), KTI India = Mixing temperature 37 °C
Temp. before mixing 49 °C
• A reliable partner for customers, 40 °C 40 °C
Iran (Tehran) + 70 kg Flake Ice
employees, suppliers and business + 100 l Ice Water
Italy (Milano), KTI Italy
partners = Mixing temperature 29 °C
Kuwait, Gulf Group
30 °C 30 °C
Responsibility Oman (Muscat), Bahwan Engineering
Qatar (Doha), KTI Qatar
KTI is well aware that its products
Saudi Arabia (Dammam, Jeddah,
use natural resources and consume 20 °C 20 °C
Riyadh), KTI Saudi
energy. The KTI concept offers custom-
Spain (Sargagossa), Arco Electronica, S.A.
ers the possibility to produce ice with
Switzerland (Sulgen), Sauter Plersch AG
the lowest consumption of energy. 10 °C 10 °C
Turkey (Ankara), Titan Makina Ltd
Production of ice can also take place Cooling with Cooling with
USA (Newport News, VA), Liebherr CT.
during the night and stored under safe Chilled Water only Flake Ice and Ice Water
conditions. With the KTI multistage Starting in the early years with a 0 °C 0 °C
cooler, the customer sees up to a 50% regional emphasis on the Middle East, 45 35 25 15 5 0
Flake Ice [kg/m3]
reduction of energy consumption com- KTI is operating today on an interna-
0 20 40 60 80 100 130 150 170
pared to conventional water chillers. tional level, providing mass concrete Water temperature [°C]
170 150 130 110 90 70 40 20 0
solutions where required independent of
Ice Water [l/m3]
climate zone and continent. 3
 Ice Water and Cold Water Plants
Ice Water and Cold Water Plants
• Up to 55% less power consumption
compared to air cooled systems due to
the use of evaporative condensers
Containerized Ice Water Plant – CIWP.4 (4th Generation) • Cold water production from 45°C down to
less than 1°C
• 4 stage cooling system (cooling tower
effect, 2 stages shell & tube evaporator,
ice bank)
• High quality semi hermetic screw
compressors
• PLC controlled with touch panel for
operation
• Compact containerized design
• Plug-in unit: Just water supply and power
supply to be connected
• Product range from 32 m³ to 450 m³/day
available
• Subcooling facility to maintain the
temperature inside the cold water tank

Prefabricated Cold Water Tanks

• Range of cold water tanks from 58 m³
to 150 m³
Containerized Cold Water Plant – CCWP.4 (4th Generation) • Prefabricated and insulated
• Including support for discharge screw
conveyors or pumps
• Support base for chillers or ice plants
Complete setup with water chiller, cold water tank,
flake ice plant and ice storage

High efficiency shell & tube Pressure control valve for Containerized cold water tank – insulated – 58 m³;
evaporators (insulated) – freezing protection chillers to be installed on top
2nd & 3rd stage cooling

High-tech semi-hermetic screw

compressors made by BITZER

Inside view of containerized

Inside view of containerized ice water plant – CIWP.4-128
ice water plant – CIWP.4-312

Evaporative condenser inside Insulated cold water tank – 150 m³ – inside steel frame for support
High-efficiency copper-coil heat exchanger CIWP.4 (1st stage cooling) Water flow control of chillers or ice storage and flake ice plant
Electronic expansion valve
for ice bank system (4th stage)

4 5
 Flake Ice Plants Benefits of Flake Ice

Prefabricated and Mobile • Fastest melting time of flake ice

compared to any other ice
• Shortest mixing time as flake ice melts
rapidly
• Longer lifespan of the batching plant
equipment and cost saving due to the
short mixing times
• The cooling energy is 100% or even
higher as the flake ice is sub-cooled
(–7°C)
• Due to the dryness, the cooling input of
flake ice can be accurately calculated and
its effects on the mixture’s temperature
is quickly apparent
• Flakes remain crisp and do not stick
together nor do they form blocks
• Flakes are free flowing Arabian Cement, Saudi Arabia 4x FLIP 86; 2x MIS 75 for
• Easy to be stored and leveled inside a up to 4500 m³/day concrete production
refrigerated ice storage with a fully
automatic ice rake system
• Easy to transport via screw conveyors or
blowing system
• No defrost losses as subcooled flake ice
is sheared from the freezing surface by
the ice removal tools

Inside view machinery container

Jirau Dam, Brazil

Flake ice 2 Collapsible ice storages

MIS 75 with 2 flake ice
Electrical switchboard with PLC control and touch panel for indication of plants (FLIP 150)
ice level and all other relevant plant performance values Ice outlet of discharge screw installed in Subansiri
dam project, India

Prefabricated ice storages Flake ice maker

Stainless steel gauge panel with

Ice maker (inside view) pressure transducers

6 7
 Ice Storages
assembled in UAE

Ice rake drive unit with flexible slip clutch

Collapsible ice storage MIS 75 under production

Transportable & Inside view MIS.4 - 60

Semi-Automatic
• Automatic loading
• Manual discharge
• Insulated ice storage
with cooling room
• Mobile 40ft container
• Integrated discharge
screw conveyors
• Power generator
optional

Inside view MIS 26 sa Transportable ice storage in Portugal

Fully Automatic Back view MIS.4 - 75
Dubai Airport – 280 tons ice production • Mobile ice storages for 19 to 90 tons
per day with 250 tons ice storage
• Integrated ice rake for automatic ice discharge
2x FLIP 280, MIS 200
• Patented air circulation and room cooling system

8 9
 Weighing & Dosing
Ice Delivery Systems • Ice delivery screw conveyors for a
• Pneumatic ice delivery efficient and fast delivery
• Ice delivery screw conveyors • Hot dipped galvanized screw conveyors
• Double discharge screw conveyor
for simultaneous ice delivery to
2 different locations
• Blowing system for ice delivery
especially long-distance
• Exact dosing of ice by integrated
weighing system

Flake ice plant with fully automatic ice storage and

pneumatic ice delivery system to two locations
Ice weighing hopper

Ice discharge and delivery screw with

metering hopper Double screw conveyor – galvanised Galvanized screw conveyor Blower outlet Weighing screw conveyor for pneumatic ice delivery with rotary valve

Metering hopper

Blower system for pneumatic ice delivery to three locations Cyclone receiver Diverter valve
Loading for transportation

Blowing station
under construction

10 11
 Dam Projects & Mass Concrete Aggregate Cooling for Dam Projects
• Wet belt cooling by ice water and silo
cooling by flooding with ice water
- Ice water chiller for wet belt cooling
producing water of less than 1°C
- Falling film evaporator insensitive
against mud and scale
- Evaporator easy to clean during
operation
- Falling film evaporator made of
stainless steel
- High efficiency due to an excellent
heat transfer between water and
aggregates
- Environment friendly refrigerant:
ammonia
- Latest screw compressor units
• Aggregate cooling by air
• Post cooling of concrete after pouring
• Sand cooling equipment
• Turnkey design
• Containerized plants to achieve the
shortest installation time
• Multiple reusability

Screw compressor unit for aggregate cooling

Water chillers for aggregate cooling

in flooded silos Air cooling unit for aggregate cooling

200 t Flake ice plant, Jirau Dam, Brazil

Falling film evaporator Stainless steel heat exchanger plates

Wet belt for aggregate cooling

Water chiller for aggregate cooling

and flooded belt conveyors

12 13
 Turnkey Installation
Step 5
Installation of the platforms
and stairways – all hot dipped
galvanised – for easy access
to the plants. All platforms
and stairways are bolted to the
frames and can be dismantled
and re-assembled for future
installations.
Step 4
Installation of flake ice plant
(e.g. FLIP 42 – with a daily
capacity of 42 tons per day)
Step 3
Installation of 2nd frame with
insulated ice storage for
75 tons flake ice including
fully automatic ice rake and
delivery system
Step 2B
Installation of intermediate
frame with ladders and platforms
to adapt the height of the ice
discharge outlet corresponding
to the batching plant
Step 2A
Installation of bottom frame
with insulated water tank
holding 150,000 liters of water
Step 1
Empty space with concrete
foundation 8 x 16 m
14
KTI Service and Sales
KTI Turnkey Installations
KTI provides simple and highly cost efficient solutions.
They require • no extra underground water tank
• no separate support construction
• no additional engineering and design work.
The modular systems of KTI are set up within the shortest
possible time.
It takes • one day for the chillers
Dubai – UAE
• two days for the flake ice plant with water
tank, ice storage, platforms and stairways
Germany
• two to three days for outside piping, cabling
and installation of the ice delivery system.
Qatar
With proper site preparation a complete concrete cooling
system will be in operation within one week.
Brazil
India
Saudi Arabia
Our Strengths Your Benefits
• Dedicated to customer care • KTI service mentality
• Regular service points in Dubai, Qatar, Saudi Arabia, • German quality standard
Germany, Brazil • Enhanced reliability
• Highly qualified teams of service technicians and engineers
• Efficient fleet of fully equipped service cars
• Optimized running costs
• Longer life expectancy
• KTI owned spare parts storage warehouses in Doha, • Minimized breakdowns
Riyadh, Jeddah, Dammam and Sao Paulo • 100% spare parts availability
• Central location of KTI warehouse in UAE • Permanent service availability
(Dubai Industrial City) • On-site training of staff at large construction sites
• 24/7 availability • Service contracts
• KTI training center in Dubai
KTI is customer-service centered. To guarantee
• Training of service staff and customer personnel by
KTI customers the smooth and reliable operation of each
German engineers according to German regulations
plant, KTI employs highly qualified teams of engineers and
service technicians worldwide. Working very closely with the
KTI overseas offices, agencies and branches, they provide
a unique after-sales customer service and support
KTI customers all the year round, everywhere in the world.
15
KTI Agencies and Registered Offices

Ankara
Tehran

Kuwait
Cairo Doha
Dammam
Riyadh Dubai
Jeddah
Headquarters KTI Muscat

KTI Saudi Arabia KTI

KTI KTI Qatar

Agencies
KTI offices
and branches
Installations

VIP KTI
KTI Saudi Arabia KTI
KTI-Plersch – KTI KTI India
Dubai Branch

KTI KTI-Plersch do Brasil

Brazil (Sao Paulo) Qatar (Doha)

KTI-Plersch
KTI-Plersch do Brasil KTI Qatar
Kältetechnik GmbH
+55 12 3126-4095 +974 55 491 286
Carl-Otto-Weg 14/2 juergen@kti-plersch.com.br raja_ktiqatar@yahoo.co.in
D-88481 Balzheim
Germany China (Beijing) Saudi Arabia (Dammam,
ice@kti-plersch.com Jeddah, Riyadh)
Tel.: +49/73 47/95 72-0

09/12 (NL 2.0 · kom DESIGN·1 GmbH Munich # 343.201201) · All rights reserved. Information subject to change without notice.
KTI Saudi Arabia
Fax: +49/73 47/95 72-22 Egypt (Cairo) +966 3 8144 382
E-mail: ice@kti-plersch.com ice@kti-plersch.com info@kti-saudi.com
www.kti-plersch.com
India (Chennai) Spain (Saragossa)
KTI India Arco Electronica, S.A.
+91 900 3099 404 +34 976 81 90 10
VIP – Various Ice Products
ravi@kti-india.com arco@arco-elect.es
Sales Representative –
Middle East for KTI-Plersch Iran (Tehran) Switzerland (Sulgen)
P.O.Box 17618 (Jebel Ali Free Zone) ice@kti-plersch.com Sauter Plersch AG
Dubai, United Arab Emirates +41 71 644 74 00
Italy (Milano)
info@sauterplerschag.com
KTI Italy
Tel.: +971/4/8 80 96 66
+39 02 75 32 404 Turkey (Ankara)
Fax: +9 71/4/8 80 99 66
mantegna@kti-plersch.it Titan Ltd Sti
Mobile: +9 71/50/4 56 04 14
E-mail: vip@vipdubai.ae +90 312 385 56 08
Kuwait (Kuwait City)
www.vipdubai.ae titan@titanltd.com.tr
Gulf Group Co.
+965 1802 803 United Arab Emirates (Dubai)
kti@gulfgroupco.com KTI-Plersch – Dubai Branch
+9 71 50 4 54 21 86
Oman (Muscat)
info@kti-emirates.com
Saud Bahwan
Projects & Equipment LLC USA (Newport News, VA)
+968 24 57 99 01 Liebherr CT
sbgsbpe@omantel.net.om +1 757 928 8547
Scan QR code with your mobile
info.lct@liebherr.com
device to view our website: Portugal
www.kti-plersch.com E-mail: portugal@kti-plersch.com