The retrofit project, completed in May 2025, replaced a 25-year-old shell-and-tube heat exchanger nearing the end of its lifecycle with a more efficient 225 TR plate-and-frame heat exchanger alternative, complete with cutting-edge liquid separation technology.

The Challenge: More Capacity, Same Space

Based in Guelph, Ontario, Canada, Sleeman Breweries has grown to become the third-largest brewer in Canada since its reopening in 1988. This growth created a common industrial challenge: their brewing operations had expanded, requiring increased refrigeration capacity to match compressor loading with evaporator demand.

Of the facility's three heat exchangers, two had already been converted to plate-and-frame heat exchanger technology, leaving the aging shell-and-tube unit as the final upgrade needed. However, the existing second-floor mechanical room provided extremely tight constraints, making a traditional equipment upgrade nearly impossible.

"Sleeman wanted a larger heat exchanger with more capacity in a second-floor mechanical room that was very tight on space, but without taking up any additional room in the facility," explains Mike Bradley, Team Lead – Ontario Industrial Project Sales, CIMCO Refrigeration.

Innovative U-Turn Technology

CIMCO's solution centered on Alfa Laval's proprietary U-turn liquid separator, designed specifically for use with plate-and-frame exchangers in ammonia applications. The module combines the separator and plate-and-frame heat exchanger to ensure minimum pressure drop losses and maximum energy efficiency.

"Traditionally, there would have been a big surge drum vessel sitting up over top of this plate, and now it's just this little separation device," Bradley explains. "It's a total game changer that dramatically reduces the space required."

The U-turn liquid separator serves the same purpose as a suction trap or surge drum, providing dry vapor directly to the compressor without requiring a separate surge drum. This bulletproof, trustworthy technology represents one of the first industrial food and beverage applications for CIMCO, although the technology is more commonly used in ice rink installations.

Partnership Enables In-House Excellence

A key advantage for CIMCO came through their partnership agreement with Alfa Laval, which allows CIMCO to build the U-turn liquid separator in their own shop rather than purchasing complete packages. This arrangement provided crucial control over lead times and customization capabilities, with the Sleeman project marking CIMCO's first in-house build of this technology.

CIMCO's in-house manufacturing approach ensures complete control over quality assurance and attention to detail throughout the production process. By keeping all fabrication, testing, and quality control internal, the team can maintain its exacting standards from start to finish.

While Alfa Laval owns the design, CIMCO's manufacturing capability enabled them to customize the installation for the specific space constraints. The team could leave out some welds and complete final construction on-site, building the equipment into the existing mechanical room rather than trying to fit oversized equipment into an already-built space.

“This level of control and focus on precision work is only possible because all aspects of the project remain in-house,” explains Bradley.

Precision Planning Through 3D Modeling

The extremely tight installation required sophisticated planning to ensure success. CIMCO employed comprehensive 3D modeling, using specialized cameras to capture detailed images of all existing piping and equipment and create a complete 3D picture of the mechanical room.

"It was a super tight installation that wouldn't have been possible without the modeling," Bradley explains.

This thorough approach prevented costly surprises during installation. Without proper planning, crews could find themselves with six workers standing around a crane holding equipment, only to discover an unexpected obstruction that forces them to stop and rework their approach. The 3D modeling allowed the team to identify and solve these challenges before the installation crew arrived on site.

Overcoming Implementation Challenges

While the 3D modeling solved the spatial challenges, other complications emerged during the project. The project met the facility’s timeline, but the installation faced some initial challenges related to controls integration. Sleeman, like many breweries, preferred to handle their own controls. This arrangement required extensive coordination and troubleshooting between CIMCO and the brewery's controls team. 

Despite these complications, the persistence and cooperation of the Sleeman / CIMCO team paid off. Bradley recalls receiving an unexpected call one morning from the customer, who thanked CIMCO for working together and collaborating on a solution and their genuine appreciation for CIMCO's commitment made the extra effort worthwhile for the team.

Triple Benefits: Footprint, Weight, and Cost

The U-turn liquid separator solution delivered three significant advantages for Sleeman Breweries: reduced footprint, lower weight, and decreased costs compared to traditional alternatives. The retrofit achieved dual objectives – providing the increased refrigeration capacity needed for expanded brewing operations while creating a cleaner, more efficiently organized mechanical room.

The Sleeman success demonstrates the potential of U-turn liquid separator technology beyond ice rinks. According to Bradley, any facility with a centralized glycol piping network would be well-suited for this technology. The project also showcases CIMCO's expertise in adapting innovative refrigeration solutions to address complex industrial challenges, demonstrating that space constraints don't limit capacity growth.