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[Webinar Recap] Preparing for the DOE’s New WICF Energy-Efficiency Standards

Julie Havenar | Product Manager – Condensing Units
Emerson Commercial & Residential Solutions

I recently conducted an E360 Webinar about the Department of Energy’s (DOE) new energy-efficiency standards on walk-in coolers and freezers (WICF). The webinar was presented to help industry stakeholders prepare for compliance by reviewing the ruling’s scope, definitions and potential industry impacts. View an archive of the webinar here and/or read a summary of its key takeaways below.

Ruling overview

On June 3, 2014, the DOE published its final rule on prescribed performance-based standards for WICFs, which specifically apply to the condensing units and unit coolers used in these systems. Then, on July 10, 2017, the DOE issued an update to the ruling and released its minimum efficiency test procedures, which they termed the annual walk-in efficiency factor (AWEF).

AWEF is a metric created by the Air-Conditioning, Heating, and Refrigeration Institute (AHRI) designed to help manufacturers validate compliance. As defined by the AHRI 1250-2009 standard, AWEF minimum efficiency requirements for dedicated condensing units vary per capacity and application (e.g., indoor, outdoor).

Although the compliance date for medium-temperature, dedicated condensing system applications has been in place since 2017, the DOE has established the following enforcement dates for 2020:

  • 1: for medium-temperature WICF applications
  • July 10: for low-temperature WICF applications

Scope and definitions

The scope of the ruling pertains to enclosed WICFs that can be walked into and have a total chilled storage area of less than 3,000 square feet. In addition, the ruling applies only to those condensing units and unit coolers designed to provide one refrigerated load. Products designed and marketed exclusively for medical, scientific or research purposes are excluded from this ruling.

According to the DOE ruling, 32 °F is the point of differentiation between walk-in coolers and freezers. A walk-in cooler is defined as an enclosed storage space refrigerated to temperatures above 32 °F. A walk-in freezer is defined as an enclosed storage space refrigerated to temperatures at or below 32 °F.

The DOE WICF ruling applies to both new and retrofit refrigeration systems, including:

  • Condensing units that are assembled to construct a new WICF
  • Condensing units that are used to replace an existing, previously installed WICF component (retrofit)
  • Condensing units used within packaged systems

Important note: While this does mean that condensing units manufactured after the ruling’s enforcement dates must comply, it does not exclude wholesalers and contractors from using and stocking condensing units that were manufactured before the DOE enforcement dates.

Industry impacts

With the DOE enforcement dates quickly approaching, stakeholders throughout the commercial refrigeration industry need to understand the ruling’s potential impacts on their businesses. Of course, this starts with equipment manufacturers that must not only manufacture compliant products, but also demonstrate certification and compliance through the following: registration with the DOE’s Compliance Certification Management System (CCMS) database; proper disclosure in marketing materials; and permanent nameplate marking.

Impacts to other key stakeholders include:

  • Wholesalers — must be prepared for changing inventories and begin carrying only AWEF-compliant products if they are manufactured after the 2020 enforcement date
  • Contractors — must understand that if they replace a condensing unit with one manufactured after the DOE enforcement date, it must be an AWEF-compliant unit
  • Design consultantsmust be well-versed in the regulatory impacts to advise end users in the selection of energy-compliant, sustainable systems
  • End usersneed to consider selecting future-proof equipment that aligns with their long-term refrigeration strategies

Regardless of your specific role, Emerson offers additional training, resources and expertise to help you prepare for compliance and understand the impacts of the DOE’s WICF ruling. For more information, please view the webinar archive or download our DOE WICF ruling FAQ document.

 

[Webinar Recap] Factoring Energy Management Into Your Refrigeration Retrofits

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

Emerson Commercial & Residential Solutions

In today’s dynamic food retail climate, many operators are wondering why they should retrofit their aging refrigeration supermarket refrigeration architecture. For most, this is a not an easy decision to make. While you’ll often find some form of a refrigerant regulation accelerating this process, a viable refrigeration retrofit should also include plans for ongoing energy optimization. In our most recent E360 Webinar, I discussed how to merge these two considerations into a sustainable, long-term refrigeration strategy. Read the summary below and/or view the webinar in its entirety.

The transition to more environmentally friendly, future-ready refrigerants is underway, and as a result, many supermarket retailers are evaluating retrofit options on their existing systems. But for large enterprises or individual stores that consume a lot of energy, the rising costs of energy (especially in certain regions with high rates) are moving conversations toward energy management — not only in refrigeration systems, but also entire facility ecosystems and across the enterprise.

Ultimately, the goal of an effective approach to energy optimization is to minimize energy costs in every way possible. Doing so requires an understanding of the various factors that contribute to energy costs, including:

  • Energy consumption profile of key store systems such as refrigeration, HVAC and lighting
  • Peak electric consumption cycles and periods in each store
  • Time of use rates as dictated by the electrical utility, including both on- and off-peak rates
  • Seasonal changes and their impacts on consumption and electricity rates

This is particularly important in certain areas of the country where charges exceed $15 per kW during peak demand periods.

Why the focus on refrigeration?

A typical supermarket uses a centralized direct expansion refrigeration architecture which accounts for more than 50 percent of its total annual energy consumption, with HVAC systems the next largest consumer at 20 percent. At the same time, an average supermarket consumes three times more energy per square foot than other retail facilities. It’s no surprise then that these systems are becoming prime targets for energy optimization in the U.S. and around the globe.

The tendency for refrigerant leaks in traditional centralized systems — most of which are also charged with refrigerants that have a high global warming potential (GWP) — makes these systems ideal candidates for retrofits. Many of them can transition to lower-GWP refrigerants with relatively minimal retrofit requirements.

Six steps along the “Journey to Energy Excellence”

In the webinar, I cited a case study of a supermarket that went through a retrofit process in its centralized refrigeration system. The process followed a methodology that Emerson refers to as the Journey to Energy Excellence. By upgrading only the refrigeration system (i.e., the first three steps below), the supermarket reduced its energy costs by nearly $40 thousand per year.

The six steps along the journey to energy excellence include:

  1. Conduct a baseline energy audit of the existing system.
  2. Recommission the system to its original condition and setpoints.
  3. Make refrigeration technology upgrades, such as: digital compressors, variable frequency drives and floating the head/suction pressures.
  4. Change the lighting and other renewable upgrades such as adding doors, electronic expansion valves and electrically commutated motors on evaporators.
  5. Expand focus to HVAC technology upgrades, including rooftop units and demand control ventilation.
  6. Deploy a condition-based maintenance, internet of things (IoT) infrastructure to accurately monitor asset and system performance.

Each step enables progressive degrees of energy optimization, and as the case study demonstrates, implementing just the first three steps can provide significant financial gains. Collectively, this methodology can help supermarkets develop energy management strategies that consider entire facility ecosystems.

Regardless of where you are in this process, Emerson is providing solutions at every step to help retailers achieve energy excellence in stores and across the enterprise.

[New E360 Webinar] Preparing for DOE Compliance on Walk-In Coolers and Freezers

Julie Havenar | Product Manager – Condensing Units
Emerson Commercial & Residential Solutions

In 2020, the Department of Energy (DOE) will begin enforcing its new energy-efficiency standards on walk-in coolers and freezers (WICF). With the compliance deadline now on the horizon, the commercial refrigeration supply chain is taking a closer look at the ruling and preparing for its impacts. Our next E360 Webinar, on Thursday, Sept. 26 at 2 p.m. EDT/11 a.m. PDT, will shed light on the details of this rulemaking.

Improving the energy efficiency of refrigeration equipment is a goal shared by most stakeholders in the commercial refrigeration supply chain. But when specific energy reductions are mandated by DOE regulations on a commonly used class of equipment, then these goals take on a much greater sense of urgency. The DOE’s 2020 WICF mandate is no exception.

Generally speaking, the ruling will require 20–40 percent energy reductions in WICFs smaller than 3,000 square feet. But, like many regulations of this kind, when you start digging into the details, you’ll find that they’re complicated and often difficult to interpret.

In our next E360 Webinar, I’ll provide a detailed overview of the DOE’s WICF ruling and discuss how it can impact you — regardless of whether you’re an equipment manufacturer, contractor, end user, design consultant or wholesaler. So, if you’re unsure about how to prepare for compliance or just curious how the ruling may impact you, then be sure to join me on Thursday, Sept. 26 at 2 p.m. EDT/11 a.m. PDT for this informative webinar. Attendees will learn:

  • The full scope of the WICF rulemaking
  • Definitions of key terms, concepts and language used
  • Final enforcement dates per equipment category
  • Examples of WICF system configurations
  • Required efficiency levels per the Annual Walk-in Efficiency Factor (AWEF) metric
  • Impacts to various stakeholders throughout the supply chain
  • How to verify and ensure compliance

As with all E360 Webinars, we will allocate time after the presentation for a question and answer session. To make sure we’re able to address your specific questions, this session will be supported by additional Emerson experts on the DOE WICF regulation, including: Roxanne Scott, senior lead project engineer; and Brian Buynacek, senior consultant. So, register now for this informative webinar and let us help you prepare for the DOE WICF compliance deadline.

 

[New E360 Webinar] Why Retrofit Your Aging Supermarket Refrigeration Architecture?

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

Emerson Commercial & Residential Solutions

Many supermarket operators face a common dilemma regarding their refrigeration systems: they know they need to make changes or upgrade their legacy systems, but they’re not sure what their retrofit options are — or even where to begin. In our next E360 Webinar, I’ll offer guidance on how supermarket owners/operators can embark on this critical journey.

Join me on Tuesday, Aug. 13 at 2 p.m. EDT/11 a.m. PDT for this informative webinar.

[New E360 Webinar] Why Retrofit Your Aging Supermarket Refrigeration Architecture?

There’s no question that reliable refrigeration is the backbone of any supermarket operation; it accounts for more than 50 percent of the electrical consumption for an average supermarket. That’s why keeping your refrigeration system running at optimal efficiency is essential to maximizing profits and ensuring operational success.

But if you’re like many owners/operators, you’ve been relying on the same centralized refrigeration architecture for decades. During that time, these systems have typically experienced declining performance levels and energy efficiencies — all due to progressive deviations from their original commissioned states. And while these systems are perfect candidates for an upgrade or a retrofit, even newer systems can offer opportunities for improvements, especially within the context of today’s rapidly evolving industry and market dynamics.

Compared to just 10 years ago, the drivers behind refrigeration decisions have changed dramatically, and the days of a one-system-fits-all mentality are quickly becoming a thing of the past. Environmental concerns, energy costs, shifting regulations, shrinking store formats, consumer demands and omnichannel delivery have all irrevocably reshaped the supermarket landscape.

As a result, more supermarket owners/operators are reevaluating their existing (and often aging) systems while looking for any retrofit opportunities that are available to them. Our next E360 Webinar is designed with them in mind. To help you better understand the many factors to consider when evaluating a supermarket refrigeration retrofit, I’ll be discussing the following topics:

  • Industry and market trends driving the need for refrigeration system retrofits
  • How to identify deficiencies and baseline performances in centralized architectures
  • A look at the potential architectures of the future
  • Recommended technologies for retrofits and recommissioning
  • Energy-efficiency strategies for refrigeration, HVAC and the complete building envelope

As always, we will take time after the presentation to answer any of your questions. So, be sure to register now and add this event to your August calendar.

10 Takeaways From 10 Years of GreenChill Data

JohnWallace_Blog_Image John Wallace | Director of Innovation, Retail Solutions

Emerson Commercial & Residential Solutions

The Environmental Protection Agency’s (EPA’s) GreenChill Advanced Refrigeration Partnership recently completed a 10-year study examining supermarket data trends. In our latest E360 Webinar, Tom Land, manager of the program, presented these findings from GreenChill’s unique perceptive. View the webinar in its entirety or read the summary below.

Latest E360 Webinar on Demand

For more than a decade, the GreenChill program has worked with supermarket retailers across the country to promote the use of “greener” refrigeration systems in their stores. While our industry is in the early phases of transitioning to more sustainable refrigeration, GreenChill partner companies are at the forefront of this movement. The number of retailers participating has increased significantly since the program’s inception, and the data Tom discussed at the webinar provides a road map for other companies as they formalize their own sustainability initiatives.

Let’s look at 10 takeaways from the recent webinar.

  1. GreenChill partnership on the rise — in 2007, just more than 4,000 stores were GreenChill partners; today, that number exceeds 11,000 stores.

 

  1. Partner refrigerant emissions remain low — among the growing number of participating GreenChill partner stores, emissions have been held to a minimum. This is in large part due to the program’s emphasis on reducing refrigerant leaks and system charges.

 

  1. Refrigerant charges are declining — the average amount of refrigerants used in participating stores has declined steadily since 2007, even as the number of stores increases.

 

  1. Pounds per store leaks are dropping — in 2007, partner stores emitted more than 390 pounds per store every year; today, 290 pounds is average.

 

  1. Leak rates well below industry averages — on average, GreenChill partners have a leak rate of 13.9 percent, well below the industry average of 25 percent. Twelve of the partners have achieved a leak rate below 10 percent.

 

  1. One-fifth still use R-22 — although R-22 use is on the decline overall, 20 percent of commercial refrigeration systems continue to use it.

 

  1. Low-GWP refrigerants on the uptake — R-407A accounts for 20 percent of partner-installed refrigerants; installations with refrigerants less than 1,420 GWP now account for nearly 3 percent of all partner-installed refrigerants, with R-448A accounting for much of this growth.

 

  1. CO2 installations increase — installations of CO2 secondary loop, cascade and transcritical booster systems among partners continue to rise, with more than 12 partners exceeding a combined total of 160,000 pounds of installed R-744.

 

  1. Growth of GreenChill certifications — in 2009, fewer than 25 stores achieved GreenChill Gold and Silver certifications; today more than 360 stores have achieved Platinum, Gold and Silver certifications and re-certifications.

 

  1. California leads certification — among those states with GreenChill-certified stores, California leads the country with 151 stores. The next closest state is Florida with 45 stores.

Over the past decade, Emerson has worked with a variety of GreenChill partners to meet their sustainability objectives, utilizing leading low-GWP refrigerant alternatives and energy-efficiency strategies. If you’re interested in transitioning to a greener refrigeration system, we’re here to help you develop a strategy that meets your long-term goals.

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