Thermal Energy Storage Systems for Dairy & Industrial Cooling
Barry Brown & Sons supplies Thermal-Store — an advanced thermal energy storage system (TES) engineered for chilled water systems, dairy farms, and industrial cooling applications throughout Australia.
Designed to maximise solar energy utilisation, improve energy efficiency, and reduce operational costs, Thermal-Store uses innovative ice ball cooling technology to store thermal energy during off-peak or solar production periods, then deploy it on demand. This allows chillers to remain offline during peak tariff windows while maintaining reliable, consistent cooling performance across your operation. The system is suitable for both new installations and integration into existing cooling infrastructure.
How Thermal-Store Works
At the core of the Thermal-Store thermal energy storage system are especially engineered ice balls housed inside a large, highly insulated glycol storage tank. During periods of strong solar generation or off-peak electricity pricing, a chiller cools the glycol solution, freezing the ice balls and storing thermal energy for later use. Once the glycol reaches the required temperature, the system becomes a dependable reserve of cooling capacity that can be deployed during peak demand periods while the chiller remains offline.
This process integrates seamlessly with existing cooling infrastructure, including mile pre-cooling systems, glycol plate heat exchangers, pumps, and storage tanks. In dairy applications, the TES process typically follows a staged cooling flow — from milk collection and plate heat exchange through to ice ball storage, pumps, control systems, and chilled milk holding before tanker collection. Combined with solutions such as Custom Glycol Chillers & Industrial Chiller Units,
Heat Recovery Systems, and Custom Electrical Control Panels, Thermal-Store delivers reliable cooling performance while reducing peak energy demand, lowering electricity costs, and improving overall energy management across the facility.
50+ Years Experience
WORLDWide Delivery
Custom Builds & Fittings
Refurbished Options Available
50+ Years Experience
AU-Wide Delivery
Custom Builds & Fittings
Refurbished Options Available
Thermal Energy Store - Downloadable Information Packs
Ready to explore TES for your facility? Download our guides to understand the system, the process, and how thermal energy storage can support operational efficiency, lower energy costs, and help facilities get started with carbon credits.
Key Benefits of Thermal Energy Storage
Thermal-Store delivers measurable operational and financial benefits for facilities where cooling performance, energy efficiency, and operating costs are critical.
Solar Optimisation
Thermal-Store maximises the value of solar energy by converting excess daytime generation into stored thermal energy. Rather than exporting unused power back to the grid, facilities can use solar energy to freeze the ice balls and create cooling reserves for later use, improving energy self-sufficiency and renewable energy utilisation.
Energy Cost Reduction
By shifting cooling loads to off-peak hours, the thermal energy storage system reduces peak electricity demand charges and minimises reliance on expensive grid power during high-tariff periods. This can significantly lower long-term operating costs for dairy farms, processing plants, and industrial facilities with high cooling requirements.
Better Milk Quality
For daily operations, rapid and consistent milk chilling is essential. Using stored glycol cooling allows milk to be chilled quickly after collection, helping preserve milk quality from the initial cooling stage through to tanker pickup while maintaining strict temperature control standards.
Carbon Offset Opportunity
Operating with solar and off-peak energy can substantially reduce a facility’s carbon footprint. Thermal-Store may also support participation in carbon reduction or carbon credit initiatives, depending on operational requirements, sustainability targets, and eligibility criteria.
Operational Flexibility
Thermal energy storage provides dependable cooling even when chiller operation is limited by energy pricing structures, carbon reduction targets, or demand response events. Stored cooling capacity gives operators greater control over when and how energy is used throughout the day.
Seamless Integration
Thermal-Store is designed to integrate with existing chilled water systems, glycol cooling infrastructure, and industrial plant equipment without disrupting day-to-day operations or production schedules. This makes the system suitable for both retrofit projects and new facility developments.
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Thermal-Store Applications
Thermal-Store is ideal for facilities seeking to integrate renewable energy, reduce peak demand costs, and improve cooling resilience across their operations.
Dairy Farms
Rapid milk chilling using ice ball stored glycol cooling helps maintain milk quality while supporting integration with solar systems and farm battery storage. Thermal energy storage systems provide dairy farms with more predictable cooling performance, lower operating costs, and improved energy efficiency during peak production.
Food & Manufacturing
Thermal energy storage supports off-peak cooling for food processing and chilled storage facilities, reducing operational costs without compromising hygiene standards or temperature compliance requirements. The system can also assist facilities looking to improve sustainability and reduce overall electricity consumption.
Commercial Buildings
Commercial buildings can use TES systems to shift HVAC cooling loads to off-peak windows, reducing peak demand charges across office buildings, retail centres, hotels, and hospitality facilities with significant air conditioning requirements.
Industrial Facilities
Industrial processing plants and manufacturing facilities benefit from reliable stored cooling capacity that supports operations with high or fluctuating energy demands while helping improve operational efficiency and long-term energy management.
Data Centres
Thermal-Store provides an effective thermal buffer for server cooling environments requiring uninterrupted, energy-efficient temperature management and cooling reliability, particularly in facilities operating around the clock.
Frequently Asked Questions
A Thermal Energy Storage (TES) system stores cooling energy for later use. The Barry Brown & Sons Thermal-Store system uses specially designed ice balls inside an insulated glycol tank to store cold energy generated during periods of solar production or off-peak electricity pricing. This stored energy can then be used when cooling demand is highest.
The ice balls act as a thermal battery. During off-peak periods or when solar power is available, chilled glycol freezes the ice balls. When cooling is required, the ice balls gradually melt and release stored cooling energy, helping maintain glycol temperatures without continuously running the chiller.
Thermal Energy Storage helps dairy farms reduce electricity costs, improve milk cooling performance, lower peak power demand, utilise solar energy more effectively, and reduce carbon emissions. It also improves milk quality by rapidly cooling milk after milking.
Yes. Thermal-Store is specifically designed to maximise the use of solar energy. Excess solar power generated during the day can be used to freeze the ice balls, effectively storing solar energy as cooling capacity for use later in the day or overnight.
Savings vary depending on site conditions, cooling demand, and electricity tariffs. By shifting energy consumption to off-peak periods and maximising solar self-consumption, many businesses can significantly reduce their peak electricity charges and overall energy costs.
Yes. Thermal-Store systems can be integrated into many existing glycol chilling and milk cooling systems. Barry Brown & Sons can assess your current setup and design a solution that complements your existing infrastructure.
Ready to Explore Thermal Energy Storage for Your Facility?
Whether you’re looking to reduce cooling costs, minimise peak demand charges, or better integrate solar energy into your operation, Barry Brown & Sons can help you determine if Thermal-Store is the right solution for your facility.
Our experienced team works with dairy farms, food manufacturers, commercial facilities, and industrial operations across Australia to deliver tailored thermal energy storage systems designed for long-term performance, operational reliability, and improved energy efficiency.
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