Agricultural Innovation

Gracemar Farms - Dairy Chiller Retrofit Project

Transforming Dairy Challenges Into Energy Solutions

Alpine Refrigeration partnered with Gracemar Farms in Chilliwack, BC, to deliver a custom dairy chiller retrofit that solved chronic ammonia issues and extended equipment life.

The retrofit integrated an advanced clean-room design and heat recovery, reclaiming waste heat to provide warm water for livestock and boiler preheat - turning a 7-year-lifecycle problem into a 25-30-year asset.

The project also opened the door to Investment Agriculture Foundation (IAF) sustainability grants for the farm, delivering financial and environmental benefits alongside the technical fix.

These upgrades created a more sustainable, cost-efficient system built to last for decades.

Six-compressor custom dairy chiller bank installed by Alpine Refrigeration at Gracemar Farms, Chilliwack

Gracemar Farms dairy chiller retrofit with clean-room layout and new equipment racks for heat recovery in Chilliwack BC

The clean-room layout and new equipment racks that replaced Gracemar's legacy plant - the old system averaged only seven years between replacements.

Gracemar Farms · Dairy refrigeration retrofit

The Challenge

Gracemar Farms was operating with outdated refrigeration equipment that created chronic ammonia issues and limited system reliability. Equipment lifespans averaged only 7 years, leading to frequent replacements, high costs, and constant maintenance demands.

The existing system also wasted significant amounts of heat energy, offering no recovery process to repurpose excess thermal output. This inefficiency raised operating expenses and missed opportunities to support livestock operations more sustainably.

At the same time, regulatory pressures around air quality and environmental compliance meant a long-term solution was needed - one that would improve safety, extend system life, and support sustainable farming practices.

Why Change Was Needed

Chronic ammonia issues creating air quality and safety risks
Short equipment lifespan (7 years on average, costly to replace)
No heat recovery, wasting valuable energy
Pressure to improve sustainability and qualify for agricultural grants

Custom piping and control system installed at Gracemar Farms dairy retrofit to improve efficiency and system reliability

Custom piping and control upgrades at Gracemar Farms boost efficiency and extend system life.

Engineered for Performance

Alpine's Hybrid Heat Pump Retrofit Solution

Alpine engineered a custom dairy chiller retrofit that addressed Gracemar Farms' ammonia challenges while extending equipment lifespan. Instead of replacing the system with another short-lived setup, Alpine designed a solution built for long-term durability and efficiency.

By integrating an advanced clean-room layout and heat recovery system, Alpine captured waste heat that had previously been lost, repurposing it to provide warm water for livestock and boiler preheat. The result: improved air quality, reduced operating costs, and a system designed to last decades instead of years.

How We Did It

Custom Chiller Design: Engineered for clean-room performance to improve air quality and reliability.
Heat Recovery Integration: Captured waste heat and repurposed it for drinking water and boiler preheat.
Durability Upgrades: Retrofit projected to extend system lifespan to 25-30 years (vs. 7 years before).
Sustainability Gains: Enabled eligibility for IAF grants supporting sustainable farm practices.

Heat recovery tanks at Gracemar Farms capturing waste energy to provide warm water for livestock and boiler preheat Chilliwack BC

Heat recovery tanks at Gracemar Farms capture waste energy to provide warm water for livestock and boiler preheat.

Verified Results

Proven Performance

Early results from the Gracemar Farms dairy chiller retrofit show a dramatic improvement in system longevity and efficiency. Equipment that once lasted only ~7 years is now projected to run for 25-30 years, cutting capital replacement costs and ongoing maintenance demands.

The retrofit's integrated heat recovery system also captures energy that was previously wasted, repurposing it to provide warm water for livestock and boiler preheat. This innovation has reduced operating expenses while supporting more sustainable farm operations.

The project further enabled Gracemar Farms to qualify for IAF sustainability grants, underscoring Alpine's role in delivering not just technical solutions but financial and environmental benefits as well.

25-30 year projected system lifespan (vs. ~7 years before)
Reclaimed heat repurposed for water and boiler preheat
Qualified for IAF sustainability grants

This retrofit gave Gracemar Farms a cost-efficient, long-term solution that improved reliability, lowered operating costs, and advanced sustainability. The design is serviceable, durable, and sets a new benchmark for agricultural HVAC retrofits across British Columbia.

25-30 Year Lifespan

vs. 7 years on the legacy plant.

Heat Recovery Built-In

Reclaimed heat preheats livestock and boiler water.

IAF Grant Eligible

Unlocked sustainable agriculture funding.

Custom refrigeration equipment at Gracemar Farms designed for efficiency, durability, and sustainable farm operations.

Beyond Gracemar Farms

Scalable Agricultural Retrofits Across BC

The Gracemar Farms dairy chiller retrofit proved that agricultural HVAC upgrades can be practical, repeatable, and scalable. By working with existing infrastructure and integrating heat recovery, Alpine created a retrofit model that avoids costly replacements while delivering long-term efficiency.

This retrofit model has already gained attention from other dairy and agricultural operations across BC. Rising energy costs and sustainability requirements mean farms need solutions that balance budget, compliance, and efficiency - and Alpine's approach delivers exactly that.

Why It Matters for BC Agriculture

Scalable model: repeatable across farms and processing facilities
Livestock-focused: supports air quality and warm water for animal health
Sustainability ready: helps farms qualify for IAF and Net Zero programs
Built to last: durable design projected for 25-30 years of service

Glycol piping on the heat-recovery loop inside the new Gracemar Farms refrigeration plant

Turning Waste Heat Into Hot Water.

A built-in heat recovery loop captures energy that would normally be lost - heat the refrigeration plant once rejected straight to outside air now preheats water for livestock and cleaning, cutting utility bills every day.

Built farm-tough

Custom Solutions for Dairy Operations.

Custom engineering, practical solutions, built farm-tough.

Lower Energy Costs Cut utility bills with custom, efficient systems.

Net Zero Carbon Ready Stay compliant with today's environmental standards.

Across Schools, Farms & Businesses Proven solutions in every sector we serve.

Custom dairy chiller system engineered by Alpine Refrigeration for Gracemar Farms Chilliwack BC

Cooling Built for Dairy's Demands

Alpine engineered a custom chiller system specifically for Gracemar Farms, ensuring consistent cooling that keeps up with dairy production and protects valuable equipment.

Water treatment and filtration unit supporting the Gracemar Farms dairy refrigeration system - Alpine Refrigeration

Industrial Safety on the Farm

The system incorporates clean-room style ammonia controls, providing industrial-grade safety standards that protect both workers and equipment.

Rugged custom piping and controls at Gracemar Farms dairy chiller retrofit designed for long-term reliability

Farmer-Friendly Reliability

The system was designed with easy-to-manage controls and a rugged build, ensuring reliable performance and lower maintenance needs for years to come.

FAQ

Gracemar Farms Retrofit FAQ.

How disruptive was the installation?

Installations were scheduled to minimize downtime. Because Alpine retrofitted existing systems instead of replacing them entirely, farm operations were able to continue with limited disruption.

Does the retrofit help reduce operating costs?

Yes. The heat recovery system reuses waste energy to heat livestock drinking water and preheat boilers, cutting energy bills while improving efficiency.

How long will the new system last?

The retrofit extended system lifespan from roughly 7 years to a projected 25-30 years, significantly reducing replacement costs.

What makes this retrofit more sustainable?

By capturing waste heat and improving reliability, the system reduces energy waste and qualifies for IAF sustainability grants, helping farms meet environmental targets.

Could this model work for other dairy or agricultural operations?

Absolutely. The design is scalable and adaptable, making it suitable for other dairy farms and agricultural facilities facing similar challenges.

What kind of maintenance is required?

Routine maintenance is straightforward. The clean-room design keeps equipment accessible, while durable components reduce the frequency of repairs.

How does this compare to a full equipment replacement?

Full replacement would have meant high costs and short service life. The Alpine retrofit approach avoids major tear-outs while delivering long-term durability.

What were the biggest improvements for day-to-day operations?

Improved air quality, reliable water heating for livestock, and reduced maintenance interruptions have all had a major impact on daily farm efficiency.

Every agricultural operation faces unique HVAC challenges

Let's Talk About Your Farm Facility.

Whether you're upgrading outdated chillers, planning a heat recovery retrofit, or working toward sustainability goals, Alpine Refrigeration brings the technical expertise and proven project experience to get the job done right. Contact us today to schedule a site assessment or consultation.

Schedule a Farm Facility Assessment · 604.795.5777