MeeFog System Boosts Air Compressor Output at Fertilizer Plant

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TLDR: MeeFog’s high-pressure fogging system helped J.R. Simplot’s Helm, California fertilizer plant boost ammonia production by up to 10% during peak summer demand, while cutting energy use and earning an EPA Energy Star rating.

J.R. Simplot, one of the largest privately held food and agribusiness companies in the nation, operates a major fertilizer production facility in Helm, California. During the region’s intense summer heat, the plant faced significant production drops right when market demand was at its peak, while also needing to lower energy consumption as part of its sustainability efforts.

Simplot installed a MeeFog high-pressure fogging system to pre-cool inlet air ahead of its air compressor, which is critical to ammonia production. The system has been providing air compressor cooling since 2007, offering up to a 10% production boost in summer months, paying for itself within a couple of seasons, and helping the plant earn an EPA Energy Star rating for four consecutive years.

Customer Profile

J.R. Simplot is a family-owned, privately held food and agriculture company headquartered in Boise, Idaho, with operations spanning food processing, phosphate mining, fertilizer manufacturing, farming, ranching, and cattle production. The company operates across the U.S., Canada, Mexico, Argentina, Australia, and China. Its Helm, California fertilizer plant, located in the San Joaquin Valley, is one of its major U.S. production facilities.

The Challenge:

During California’s intense summer months, Simplot’s Helm fertilizer plant faced significant drops in production at the very time when demand was at its peak. The facility needed a solution that would boost output and while lowering energy consumption as part of ongoing sustainability efforts.

The Solution:

Implementation of the MeeFog system, which reduced inlet air temperatures by up to 30°F. This adaptation was critical in boosting the efficiency and output of the air compressor used in ammonia production, which is vital during high-demand periods.

The Installation:

The MeeFog system comprises eight stages of cooling. Each cooling stages has seven fog nozzles for a total of 1.8 gallons per minute of water. The water is converted into micro-fine droplets by Mee’s patented impaction pin nozzle. These nozzles are designed to prevent the formation of large droplets and to ensure that droplet sizes are maintained below 20 microns.

Fog System Benefits at Helm, CA:

The MeeFog system at the J.R. Simplot fertilizer plant in Helm, CA has been operating since 2007, more than 15 years. Initial costs were recouped over the first couple
of summers due to a significant increase in ammonia production. As maintenance work is nominal, the system has paid for itself many times over.

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What Was the Strategy MeeFog Used

MeeFog designed the air intake cooling system around eight sequential cooling stages, each fitted with seven fog nozzles, to progressively reduce inlet air temperature ahead of the air compressor.

The patented impaction pin nozzles atomize water into micro-fine droplets under 20 microns, using a total of just 1.8 gallons per minute across the system. This staged approach delivered a reliable 30°F drop in inlet air temperature. It directly improved compressor performance during the plant’s highest-demand summer periods.

Key Outcomes

Up to 10% power boost during hot summer months
Inlet air temperatures reduced by up to 30°F
Initial costs recouped within the first couple of summers
EPA Energy Star rating earned for four consecutive years
Plant energy consumption reduced by 25% over the past decade due to a series of upgrades and modifications
System has run since 2007, more than 15 years

Key Benefits of MeeFog’s High-Pressure Fogging System Explained

Improved Compressor Performance

Cooling compressor inlet air helps increase air density, allowing compressors to process more air and improve output.

Better Hot Weather Operation

The MeeFog air intake cooling system helps maintain compressor efficiency when rising temperatures reduce natural air density.

Efficient Evaporative Cooling

Ultra-fine water droplets evaporate quickly and absorb heat from the air stream, creating an effective evaporative cooling effect.

Lower Energy Demand

Cooler inlet air allows compressors to move air more efficiently, which can help lower energy consumption in the long run.

“Running the MeeFog system during the summer months results in about 5 to 10% increase in production compared to running without.”

-Agus Sumantri, Engineer and Production Manager at J.R. Simplot

Lifecycle Performance and Cost Benefits!

Initial investment recouped in 1–2 summers
Nominal ongoing maintenance costs
System paid for itself many times over
15+ years of operation since installation
Contributes to lower plant energy consumption

Why Choose MeeFog

Over 50 Years of Experience

MeeFog has been designing and installing high-pressure fogging systems for over five decades, helping demanding industrial processes improve efficiency.

Proven Installations Worldwide

We’ve installed more than 10,000 systems across industries around the world, including power generation, manufacturing, agriculture, pharmaceutical, and fertilizer production.

Advanced High-Pressure Fogging Systems

Our impaction pin nozzles deliver consistent sub-20-micron droplets, providing precise inlet air cooling that translates directly into efficiency gains.

See How MeeFog Can Improve Your Industrial Operations

For more than 15 years, MeeFog’s high-pressure fogging system has helped Simplot’s Helm plant boost ammonia production by up to 10% during peak summer demand, while cutting energy use and paying for itself many times over. If your facility faces similar seasonal output challenges, MeeFog’s proven technology can help.

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Learn More about MeeFog Systems

Want to see what MeeFog’s high-pressure fogging system can do for your facility’s output and efficiency? Contact us today to request a quote tailored to your operation.

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John Mee

40+ Years at Mee Industries Inc. | Leveraging deep technical expertise to solve complex environmental control challenges. I combine digital strategies with old-school relationship building to expand market reach. Dedicated to advancing the application of fog technology while maintaining the highest standards of client trust and service.