Commercial seafood processing depends on refrigeration systems that perform consistently every hour of every day. Whether storing live seafood, frozen products, or temperature sensitive exports, even minor refrigeration failures can result in product loss, production delays, increased operating costs, and compromised food safety.
For businesses operating within the seafood processing industry, refrigeration is not simply another utility. It is a critical production asset that protects inventory, maintains export quality standards, and supports uninterrupted operations.
This case study highlights how Glotech Group successfully completed one of its most technically demanding industrial refrigeration upgrades for Combined Abalone in Hermanus. The project involved replacing ageing condensers, upgrading corroded refrigeration pipework, repairing multiple evaporators, and redesigning the refrigeration system to restore reliable long term performance.
Rather than continuing with temporary repairs that had become increasingly expensive, the client invested in a complete refrigeration system upgrade that permanently addressed the root causes of the recurring failures.
Combined Abalone operates within one of South Africa’s most demanding food processing industries. The company specialises in the processing, importing, and exporting of canned fish, live seafood, and frozen seafood products for local and international markets.
Products of this nature require carefully controlled storage temperatures throughout processing and distribution. Any interruption in refrigeration performance can affect product quality, reduce shelf life, and increase financial risk.
Because seafood is highly perishable, maintaining a dependable freezer system is essential to daily operations.
When Combined Abalone contacted Glotech Group, the facility had been experiencing persistent refrigeration problems for an extended period.
The primary freezer system struggled to maintain consistent operating temperatures.
The maintenance team found themselves regassing the refrigeration system almost every week simply to keep the freezer operational.
While refrigerant recharging temporarily restored performance, the improvement never lasted.
Weekly refrigerant replacement had become:
More importantly, the refrigeration instability placed valuable frozen seafood products at unnecessary risk.
The business needed a permanent engineering solution rather than another temporary repair.
Our technicians carried out a detailed inspection of the complete refrigeration installation.
Instead of focusing only on the symptoms, we assessed every major component of the system.
The inspection included:
The findings quickly explained why refrigerant loss had become such a frequent problem:
The largest issue was discovered within the condensers.
Numerous refrigerant leaks were identified across the condenser assemblies.
Years of operation had left the condensers severely deteriorated.
The metal surfaces showed extensive wear, and multiple leak points were present throughout the equipment.
Although isolated repairs were technically possible, they would only have delayed further failures.
The condensers had reached the end of their service life.
Rather than spending significant money on repeated repairs with limited longevity, Glotech Group recommended replacing the condenser assemblies completely.
This approach would provide a reliable long term solution while restoring overall refrigeration efficiency.
During the inspection, attention also turned to the refrigeration pipework.
Several sections of the pipe run showed visible corrosion.
Leak testing confirmed refrigerant loss around multiple joints along the system.
Pipework corrosion is often overlooked during refrigeration repairs, yet it can become one of the largest contributors to recurring refrigerant loss.
Leaving deteriorated pipework in place would have compromised the performance of any new refrigeration equipment installed.
For this reason, the decision was made to replace the affected pipe run as part of the overall system upgrade.
This ensured the refrigeration system would perform as a complete engineered solution rather than a collection of repaired components.
The freezer system included eight evaporators supplying cooling throughout the facility.
Locating refrigerant leaks within a system of this size required extensive testing.
Each evaporator had to be individually isolated and removed from operation before pressure testing could begin.
This process required careful planning to minimise disruption while ensuring every component was thoroughly inspected.
After systematic testing, three evaporators were found to have developed refrigerant leaks.
Unlike the condensers, these evaporators remained structurally sound.
The leaks were successfully repaired, pressure tested, and returned to service.
By repairing these evaporators rather than replacing them unnecessarily, Glotech Group delivered a cost effective solution without compromising long term reliability.
One of the most technically demanding aspects of the project involved designing the replacement condenser system.
Industrial refrigeration equipment cannot simply be replaced with equipment of similar physical dimensions.
Every refrigeration component must be correctly matched according to:
Our refrigeration system designer carried out detailed sizing calculations to ensure the replacement condensers would provide the correct balance of refrigeration capacity and operating efficiency.
This engineering stage was critical to the long term success of the project.
Correct sizing ensures:
The final condenser design represented a significant upgrade over the original installation.
Because of the specialised nature of the refrigeration system, standard off the shelf condensers could not be used.
Custom condensers were manufactured specifically for the project.
The manufacturing process required approximately six weeks from order to delivery.
Although this extended the overall project timeline, it ensured the new equipment was built precisely to the engineering specifications developed during the design stage.
Waiting for correctly manufactured equipment ultimately delivered a far superior result than attempting to adapt unsuitable standard components.
Once the new condensers arrived on site, Glotech Group mobilised the installation team immediately.
The upgrade was completed over five days.
The project included:
Careful project planning allowed the installation to progress efficiently while maintaining high workmanship standards throughout the upgrade.
Following commissioning, the refrigeration system demonstrated immediate improvements.
The previous refrigerant losses had been eliminated.
System pressures stabilised.
Cooling performance became consistent throughout the freezer operation.
The compressors were now operating under properly balanced refrigeration conditions.
Most importantly, the business no longer faced the ongoing cost and inconvenience of weekly refrigerant recharging.
The upgraded refrigeration system now provides dependable cooling performance capable of supporting the demanding requirements of seafood processing and export operations.
The completed refrigeration upgrade delivered several measurable benefits.
These included:
Most importantly, the client now operates with confidence knowing the refrigeration system has been engineered for long term performance rather than temporary repair.
Projects of this complexity demand far more than refrigeration repair experience.
They require system design expertise, accurate refrigeration load calculations, advanced leak detection, custom equipment specification, and careful installation planning.
With more than 15 years of experience, Glotech Group delivers complete commercial and industrial refrigeration solutions for businesses across South Africa.
Our services include:
Every project begins with understanding the client’s operation before recommending the most effective engineering solution.
The Combined Abalone refrigeration upgrade demonstrates Glotech Group’s commitment to solving the root cause of refrigeration failures rather than applying temporary fixes.
By replacing obsolete condensers, upgrading deteriorated pipework, repairing leaking evaporators, and designing a correctly engineered refrigeration solution, the project transformed an unreliable freezer system into a dependable production asset.
For seafood processors, food manufacturers, exporters, and businesses that depend on precise temperature control, reliable refrigeration is essential to product quality and business continuity.
Whether upgrading an ageing refrigeration plant, installing a new industrial freezer, designing a commercial cold room, or modernising an existing refrigeration system, Glotech Group delivers engineered solutions built for performance, efficiency, and long term reliability.
Across Cape Town and throughout South Africa, we continue to help businesses protect valuable products, reduce operating costs, and improve refrigeration performance through expertly designed installations, repairs, upgrades, and preventative maintenance backed by more than 15 years of industry experience.
067 153 8332
info@glotechgroup.co.za
Gotech Group offers emergency repair, replacement and installation of industrial and commercial refrigeration units restoring efficient operations in Hermanus & across Western Cape.