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Posts from the ‘Food Retail’ Category

How Emerson Is Taking on Today’s Most Pressing Refrigeration Challenges with Copeland Scroll ™

Phil Moeller | Vice President – Product Management, Refrigeration
Emerson Commercial & Residential Solutions

Since its introduction nearly 30 years ago, the Copeland Scroll has revolutionized the standards for refrigeration performance and reliability. An article from the E360 Product Spotlight provides an overview of Emerson’s recent innovations for the Copeland Scroll. Click here to read the article in its entirety.

How Emerson Is Taking on Today’s Most Pressing Refrigeration Challenges with Copeland Scroll ™

The commercial refrigeration industry has changed drastically in recent years due to new regulations and consumer trends. Operators demand an ever-widening spectrum of applications, from large centralized systems to small walk-in freezers and coolers. Energy efficiency and environmental sustainability have become business priorities. And digital technologies promise connected, predictable visibility to refrigeration systems.

That’s why Emerson’s research and development (R&D) teams for Copeland Scroll have come up with innovative technologies that optimize performance and reliability, helping you take on these emerging challenges.

Innovations that bring more power, flexibility and advanced capabilities to the Copeland Scroll lineup

Wider application and temperature ranges: We’ve expanded the ranges of commercial applications for Copeland Scroll compressors, now spanning fractional ¾ horsepower ZF*KA compressors designed for low temperatures up to the 17 horsepower K5 compressor for low- and medium-temperature applications. You’ll find a variety of solutions within this horsepower range for your low-, medium- and extended medium-temperature applications.

Inherently robust product designs: Minimalistic, fully hermetic Copeland Scroll designs use up to 70 percent fewer moving parts than semi-hermetic, reciprocating compressors. That means they have no complex suction and discharge valves; can start under any system load; eliminate many vibration issues; improve liquid and debris handling; and, with their compact and lighter-weight designs, make servicing easier.

Energy compliance: Original equipment manufacturers (OEMs) rely on Copeland Scroll technology to help meet the Department of Energy’s annual walk-in efficiency factor (AWEF) ratings for walk-in coolers and freezers. Copeland Scroll’s inherent efficiency and reliability are the foundation of AWEF-compliant condensing units in leading OEM equipment design strategies.

Alternative, lower-GWP refrigerants: The Copeland Scroll lineup includes many compressors rated for use with lower-GWP synthetic and natural refrigerant alternatives. We continue to evaluate and test emerging refrigerants to help operators achieve their performance and sustainability goals.

Performance-enhancing technologies: Emerson R&D teams for Copeland Scroll lead the industry in rolling out performance-enhancing innovations, from digital modulation capabilities to liquid- and vapor-injection options and lower condensing operation. These technologies improve system reliability and capacity while meeting today’s demanding regulatory requirements.

Smart diagnostics and protection: Today, many Copeland Scroll compressors are equipped with on-board CoreSense™ Diagnostics. CoreSense provides advanced motor performance monitoring and protection, diagnostics, power consumption measurements and communication capabilities. Other compressors can be retrofitted with our panel-mounted, remote diagnostic systems. This active protection technology is driven by advanced algorithms and fault detection logging and histories, helping enable technicians to quickly diagnose and repair systems.

Product development partnerships: As an Emerson customer of Copeland Scroll, you have access to Emerson’s extensive capabilities to support your own product development efforts, collaborating with us on application engineering; design, testing and certification services; proof of concept; and application development.

Closer ties to the industry’s largest support network: Copeland Scroll compressors are backed by a network of more than 1,000 Copeland-authorized locations and over 600 certified Copeland technical specialists — a base of operations that can quickly deliver the products and technical assistance you need. Our new, fully featured Copeland™ Mobile app connects to the Emerson Online Product Information database for on-the-go access to 30 years of compressor products and specifications. It can help you quickly troubleshoot and diagnose issues and connect to our wholesaler network to check local availability of replacement products.

 

With a legacy of innovation and an eye toward the future, you can be sure that Emerson will continue to evolve to meet today’s rapidly changing commercial refrigeration requirements. To learn more about our innovations and emerging technologies, read the full E360 article.

 

Evaluating Supermarket Energy Management Strategies

JamesJackson_Blog_Image James Jackson | Business Development Manager
Emerson Commercial & Residential Solutions

I recently authored an article for Facility Executive that discussed how energy management systems (EMS) are helping to reshape how the food retail industry approaches energy efficiency and demand planning. Read the full article here.

Evaluating Supermarket Energy Management Strategies

Corporations and consumers alike are always looking for ways to reduce energy costs. Nowhere is this more applicable than in supermarkets, where chains have many energy optimization opportunities among refrigeration, HVAC and lighting systems. The average 50,000 square foot store incurs $200,000 in annual energy costs, resulting in 1,900 tons of CO2 emissions (the equivalent of 360 vehicles) in one year. Of these costs, refrigeration and lighting account for more than 50 percent of total energy usage.

As the energy and utilities sectors continue to evolve, traditional approaches to energy management and demand response must also adapt to the changing landscape. Fortunately, with advances in EMS and controls technologies, food retailers can apply automation to achieve energy best practices. These tools not only provide full building ecosystem optimization but also help operators capitalize on the potential for energy savings via utility energy incentives and available demand management opportunities.

Consumption and Demand — The Difference

Understanding the difference between consumption and demand is essential for energy management planning. Consumption is measured in kilowatt hours (kWh) and refers to the amount of energy used during a billing period. Demand represents the instantaneous energy load that a commercial customer (or building) places on the grid. Utility providers use this for base infrastructure planning and to determine total load requirements of the electrical system. When demand increases, providers must draw from additional — and often more expensive — resources like coal and other fossil fuels.

Utilities measure demand in kilowatts (kW) based upon the actual power a consumer draws. Because demand costs can be potentially higher than consumption — with charges ranging from a few to several dollars per kW — demand can account for a significant portion of a monthly bill.

Evolving Demand Response

Due to the rise of renewable generation, utility providers across the country are rethinking how to develop and deploy demand response programs. Researchers at the Lawrence Berkeley National Laboratory (LBNL) in California conducted a study that evaluated the state’s energy dynamics. The study showed that California is benefiting from an increase in solar power and the continued shift of demand from midday to evening hours. The addition of smart thermostats and controls in commercial and residential sectors is also helping the state optimize energy consumption.

The LBNL study findings are helping researchers understand the amount of flexible customer load available and evaluate different methods for getting customers to change energy consumption habits, such as time of use, peak pricing programs, and day- and hour-ahead energy market plans.

The opportunity to shift demand is seen as the greatest contributor to future grid flexibility — and potentially one of the biggest opportunities for energy savings.

Energy Management Solutions

Today, advances in EMS software and controls platforms are helping operators connect with utilities and automate their energy management programs. Among other emerging strategies used by supermarket operators are self-generation via thermal and battery storage and grid-interactive buildings.

Self-generation via Thermal and Battery Storage

Most utility providers encourage consumers to implement proven thermal and battery storage options to help shift demand from peak to off-peak hours. The concept of self-generation is simple: thermal (ice) creation and battery charging take place during off-peak hours to store energy that can be used during peak hours to help utilities offset demand.

Grid-interactive Buildings

As IoT-enabled EMS and smart devices provide unprecedented connectivity between consumers and utility companies, opportunities for greater cooperation and energy optimization are also on the rise. At the Department of Energy (DOE), the Building Technology Office (BTO) is conducting research through its Grid-interactive Efficient Building (GEB) initiative. One of their primary goals is to enable buildings to become more responsive to the electric grid conditions.

These and other tools can help facilities improve energy efficiency and achieve operational success in a quickly evolving energy market. At Emerson, we’re helping to simplify energy management challenges with smart EMS software and proven controls platforms designed to help supermarket and restaurant operators connect with utilities and automate energy-saving best practices.

How ProAct™ Connect+ Software Manages the Tasks That Matter Most for Retailers

ronchapek_2 Ron Chapek | Director of Product Management/Enterprise Software

Emerson Commercial & Residential Solutions

Today’s supermarket, restaurant and convenience store operators face an increasingly complex retail environment. A recent article in E360 Outlook Product Spotlight demonstrates how the Emerson ProAct Connect+ platform and software modules give you a sharp picture of the most critical facets of your multi-site operations. Click here to read the article in its entirety.

How ProAct™ Connect+ Software Manages the Tasks That Matter Most for Retailers

Seamlessly connect and actively manage your multi-site food retail operations

Today, consumers demand premium food quality, variety and convenience, with an exceptional, consistent shopping experience, regardless of location. Retailers need the tools that can help them quickly adapt to customer preferences and trends, ensure a high level of customer satisfaction, and ensure the quality and safety of their food — in every store within their multi-site network.

That’s why Emerson has leveraged its site management software legacy to develop the next-generation ProAct Connect+ Enterprise Software Suite.

By connecting devices and controllers to the cloud, Connect+ provides near real-time access to a wide range of critical information from anywhere in your multi-site operations to help you immediately track, evaluate and respond to issues — all from one centralized location. Backed by Emerson’s deep domain expertise in refrigeration systems, controls, facility management, data analytics, cloud connectivity and the Internet of Things (IoT), Connect+ helps multi-site retailers achieve their critical customer service and business objectives faster, with less risk, by focusing on the tasks that matter most.

Core software modules address critical operational challenges

The Connect+ platform is a scalable, customizable and robust toolset of software modules that enable multi-site performance optimization by gathering and analyzing a broad range of data about many critical functions, including:

  • Data acquisition: providing secure data acquisition, storage and aggregation
  • System management: helping monitor, manage and optimize performance in key facilities, including refrigeration, HVAC and lighting
  • Advisory management: alerting your enterprise and facility managers of any issues in the network, helping them to quickly view, evaluate and respond to issues or alarm states that could impact your operations
  • Setpoint management: continuously monitoring and optimizing temperature setpoints to help drive energy efficiency and ensure food quality and safety
  • Condition-based maintenance: improving the effectiveness of your maintenance teams by providing both real-time and historic data about equipment performance, helping them detect and address potential problems before they can impact operations
  • Food quality reports: automating reporting of Hazard Analysis and Risk-Based Preventive Controls (HARPC) food safety documentation requirements, helping you demonstrate that you are assuring consistent food quality and safety while minimizing food spoilage and waste
  • Energy management: automatically optimizing energy consumption in your systems and facilities to drive cost savings throughout the enterprise
  • Push updates: informing hundreds or thousands of connected sites and systems about important store or customer service initiatives or technical equipment update information in hours instead of days

Making high-end software easy to use

For all its capabilities, Emerson designed Connect+ to be fast, flexible and secure — and with features such as color-coded network maps, alarm visibility and intuitive navigation — remarkably easy to use.

By connecting devices and controllers to the cloud for comprehensive data management and analytics, ProAct Connect+ provides the architecture, information and intelligence to help you address today’s challenges while scaling to meet tomorrow’s demands. To learn about even more of its capabilities and the user-friendly functionality you can expect from the ProAct Connect+ software suite, read the full E360 Outlook article.

 

Integrated R-290 Cases Expand Into U.S. Markets

AndrePatenaude_Blog_Image Andre Patenaude | Director, Food Retail Marketing & Growth Strategy, Cold Chain

Emerson Commercial & Residential Solutions

I was recently asked to contribute to an Accelerate America article about the increasing use of R-290 in the U.S. commercial refrigeration market. The article featured a variety of perspectives from supermarket operators and equipment manufacturers. Read the full article (pg. 38) and more on Emerson’s perspective below.

Integrated R-290 Cases Expand Into U.S. Markets

A growing number of American retailers — including Target, ALDI US and Whole Foods Market — have been deploying self-contained, R-290 cases as spot merchandisers in hundreds of stores, many of which are mainly served by centralized rack systems. Some retailers regard these units as partial or even full-store alternatives to using a centralized rack-based system.

Obviously, this comes as no surprise to Emerson. Not only have we been partnering with R-290 equipment manufacturers for many years, we also support operators and commercial refrigeration designers alike in their efforts to utilize R-290 — and a variety of other lower-GWP and natural refrigerants — in their systems. As others have stated in the article, this trend reflects a shift in the research and development processes for some manufacturers, in that fewer emerging architectures are being designed to utilize hydrofluorocarbon (HFC) gases.

It’s further evidence that, regardless of the unpredictable state of environmental regulations, R-290 use in commercial refrigeration continues to gain traction. We at Emerson are seeing the use of integrated case architectures — where one or more R-290 compressors is/are housed within a refrigerated case — and the continued use of completely self-contained units as the most likely paths to wider adoption of integrated R-290 in 2019 and beyond.

While R-290 systems may have originally been born out of necessity to address environmental concerns, today they’re perceived in the market as much more than just eco-friendly alternatives. With the expansion of smaller-format stores and increasing retail urbanization, many times there simply isn’t enough space to accommodate a machine room for a traditional central system. In these scenarios, plug-and-play, low-charge, R-290 systems are an ideal fit.

The safe use of R-290, which is classified as an A3, highly flammable refrigerant, is governed globally by the International Electrotechnical Commission (IEC) and nationally by the Underwriters Laboratory (UL). Historically, these standards mandated that R-290 charge limits should be limited to a maximum of 150g. However, the IEC recently updated their standard (IEC 60335-2-89) to allow the use of up to 500g of A3s like R-290. This charge limit increase will enable more application flexibility for European food retailers.

It’s important to note that in the U.S., the UL standard still mandates a maximum of 150g charge limit for A3s. Even with the low charge limit of 150g, R-290 cases have proven viable options for many leading retailers in the U.S. market and abroad.

While the industry adapts to the charge limit increase, there are real-world installations that are also indicative of the safety and reliability of these self-contained, R-290 cases. Since 2013, an HEB grocery store in San Antonio has utilized the R-290 cases installed throughout the entire store as its primary refrigeration source. The designer of that architecture, who was also interviewed in the same article, stated that these cases have proved to be both safe and reliable — and have had no leaks since they’ve been installed.

Today we’re achieving more flexibility using R-290 systems with micro-distributed architectures utilizing integrated cases. They are designed to remove compressor exhaust heat via a shared glycol water loop that’s directed to the roof of the facility for heat removal. These systems typically stay within the 150g limit and enable a greater degree of scalability.

It will be interesting to see how the possibility of increasing the R-290 charge limit, as has been discussed and studied within the industry for years, might impact system design in the future. For now, R-290 seems to have a place — albeit a relatively niche one — in U.S. markets.

Advances Continue in Cold Chain Tracking Technologies

AmyChildress Amy Childress | Vice President of Marketing & Planning, Cargo Solutions

Emerson Commercial & Residential Solutions

This blog summarizes an article from Snack Food and Wholesale Bakery, “Advances in cold chain technology for snack and bakery warehousing and transport.” There have been significant technological advances in recent years to enable better temperature and condition monitoring, including key offerings from Emerson. Read the full article here.

In recent years, the Food and Drug Administration (FDA) has pressed for increased monitoring and documentation of refrigerator and freezer temperatures at every point along the cold chain to detect when cold storage temperatures fall out of the transported food’s safe range. Heightened awareness of foodborne illness as a serious health problem has driven advanced monitoring systems that trigger alarms and notify personnel should temperature conditions deteriorate.

However, these advanced systems are largely the domain of processing plants, warehouses and supermarkets, fixed locations where continuous monitoring and wireless data collection and processing are incorporated into an IT infrastructure — but they’re quickly earning industry-wide adoption.

When a food shipment is transferred to a truck, train or ship, accessing and documenting its temperature data becomes problematic and limited. Historically, food transport has been the weakest link in cold chain tracking. That’s why it’s become increasingly important to track temperature data on frozen and refrigerated food in transit to ensure food security and provide operators with end-to-end documentation.

This is where the latest advances in cold chain technology come in: the development of monitoring systems that include data loggers, i.e., electronic devices that communicate with sensors to collect data over time. When fully automated, they can eliminate the errors of manual tracking and recording information during transit, transmitting and storing continuous temperature data in real time.

Emerson Cargo Solutions is one of several companies working to fill data gaps during transit, with a suite of cellular monitors and loggers — GO Real-Time Trackers — which track and log the status of perishable products shipped across the entire cold chain, all in real time. Using cellular technology and the processing capabilities of the IoT, GO Real-Time Trackers can continuously transmit and log temperature and location data and send alerts from the loading dock to the shelf.

GO Real-Time Trackers are affordable, easy to use, and small enough to fit in the palm of one’s hand, making them particularly functional for tracking and logging goods in transit. Yet they also provide global visibility to shipments while transmitting temperature data to end users’ systems via the cloud and the IoT.

To use a GO Real-Time Tracker, a worker simply pulls a tab to start the device, places it in a container or trailer, and inputs its serial number into Emerson’s Oversight Exchange Data Integration app. From there, end users have access to comprehensive and automated monitoring. Logging data is encrypted for security and transmitted cellularly to the cloud and IoT for real-time processing and analysis. With either a smartphone or tablet, a user can check shipment status and generate documentation on the go. And the real-time data and documentation that GO Real-Time Trackers are capable of collecting are extensive:

  • Maps, graphs and charts of shipments with location and temperature details
  • Shipment summary reports using GO Real-Time Tracker serial numbers
  • Current product temperatures, temperature ranges and mean kinetic temperatures
  • Trip name, current trip status, location and duration
  • Total time out of cell range, above range and below range
  • Temperature graphs
  • Alarm events

End-to-end, real-time cold chain temperature monitoring and logging with GO Real-Time Trackers provide a higher level of overall security. Users can identify and fix previously unknown problem points in the cold chain. IoT connectivity and cellular communication make it possible for apps to monitor temperatures at set parameters throughout transport. And GO Real-Time Tracker documentation provides transparency, generating comprehensive reporting to comply with regulatory agency requirements for food safety.

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