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Posts tagged ‘Food Retail’

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.

Transforming Data Into Maintenance Insights

ronchapek_2 Ron Chapek | Director of Product Marketing

Emerson Commercial & Residential Solutions

Today’s supermarket, restaurant and convenience store operators have an abundance of data at their fingertips. Most utilize facility management systems and controls to monitor refrigeration, HVAC, lighting and energy management. These platforms give them ability to respond to alarms that could impact customer comfort and food quality. But alarms are only the “tip of the iceberg” when it comes to this data’s potential usefulness. In a recent E360 article, we discussed how operators can transform this data into maintenance insights.

While many companies spend their time tracking, prioritizing and responding to alarms that need immediate attention, owners and operators have relatively limited visibility into overall operational status. But with deeper analytics of available data, operators can look “beneath the hood” of key systems and gain access to insights that could impact them in the future — insights that could potentially transform maintenance activities from a primarily reactive approach to a more condition-based, analytics-driven model.

The difference between “urgent” and “important”

One way to visualize the role of operational analytics in maintainance activities is by prioritizing maintenance events according to their urgency or importance. Maintenance events and operational decisions can be divided into four basic categories:

  • Don’t roll a truck (no action required)
  • Roll a truck soon (plan to take action)
  • Roll a truck now (take action now)
  • Take steps to improve (address at next scheduled maintenance)

Using the iceberg analogy, urgent issues represent events that you will need to respond to immediately — those that lie above the surface. Below the surface, you’ll find issues where analytics platforms can help operators make maintenance decisions based on their potential business impacts. Analytics can help identify issues that, while not urgent, are highly important — and may have otherwise gone unnoticed.

These insights often reveal areas of improvement that could either be addressed during scheduled service intervals or when the equipment or system condition indicates the need to address a potential issue. Armed with this knowledge, operators can receive advance notice of certain performance issues that may soon impact them.

Drive performance across the enterprise

The role of analytics within a maintenance framework can be extrapolated across an enterprise to maximize its potential. Drawing from a combination of equipment sensors and control system data, performance analytics can provide store operators and enterprise managers deeper insights for:

  • Real-time and historic operating conditions in their facilities and systems
  • Pressure, temperature and energy data to compare to established benchmarks
  • Enterprise- and store-level dashboards and prioritized notifications

For example, analytics allows for display case performance analysis based on temperature sensor data. Data may detect an anomaly in case temperature deviations that, while still within safe ranges, could indicate a larger performance issue. Instead of being notified with an urgent alarm, operators have advance notice to investigate issues at their discretion — and even preempt a potentially larger issue.

Enterprise operational dashboards can also be configured to display these insights and provide managers with visual snapshots of urgent and pending issues across their store networks — even enabling investigation into specific assets in their respective facilities.

If you’re ready to see what lies below the surface of your operational data and realize the true potential of analytics, contact Emerson to speak to one of our enterprise data analytics experts.

 

Protecting Food on the Move

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

Emerson Commercial & Residential Solutions

The cold chain in perishable food distribution is a complex and delicate thing. Just one hour out of optimum temperature range can have significant impact on a product’s shelf life. More serious cold chain lapses can pose waste, food safety and environmental issues, causing businesses and entire industries financial and reputational harm. At the E360 Forum in Houston last fall, I shared common cold chain pitfalls, real-world case studies and best practices for successfully navigating this complicated process. Read more below, then view the full E360 Forum presentation.

Those blueberries on your cereal? They’re from Chili. That orange? South Africa. Today’s food travels incredible distances to get to you. And behind your grilled salmon supper, there’s a dizzying array of complex cold chain management and monitoring that needs to happen to get it to your table — safe and tasty.

Industry experts say that from farm (or ocean) to your fork, there can be as many as 15–20 transfer points (hand-offs) in the cold chain process, encompassing trucks, containers and even planes. Each stop increases the risk of food safety incidences, spoilage and lost profits.

What’s at stake when the cold chain breaks?

Food and resource waste

One of the more frustrating things to me is the amount of time, money and resources spent producing food and getting it to where it needs to go — only to have it spoil by the time it gets to the point of sale. Think of all the work, expenses, fuel and greenhouse gas emissions it requires to get product from California to the East Coast. When there’s a break in the cold chain, all of that time, effort and money could potentially be lost.

According to Food Foolish by John Mandyck and Eric Schultz, the amount of food waste in the supply and distribution of food is staggering. They estimate that:

  • 1 billion metric tons of food is lost or wasted each year
  • One-third of food produced each year is never eaten
  • 800 million people in the world are chronically hungry

In addition, food waste has a devastating impact on the environment in terms of water waste and the creation of greenhouse gases. Mandyck and Schultz go on to say: “If food waste were a country by itself, it would be the third-largest emitter of greenhouse gases behind China and the U.S.”

Financial impacts

I don’t need to tell you there’s big money in each trailer transporting food commodities across the country and around the world. If there’s a break in the cold chain, the financial impacts can be painful. Check out the food value estimate per truckload:

  • Beef — $150,000 to $250,000
  • Poultry — $60,000 to $225,000
  • Pork — $80,000
  • Strawberries — $20,000
  • Bananas — $16,000

Food safety and public health

According to the CDC, about 48 million people (1 in 6 Americans) get sick, 128,000 are hospitalized, and 3,000 die each year from foodborne diseases. Not all issues are directly attributable to compromised cold chain processes. But with elevated temperatures, a very small situation can grow exponentially in a very short time. By properly managing temperature, you can mitigate and isolate a potential food incident before it can spread.

Conquering the cold chain

We know what can go wrong when temperatures aren’t right. But how can broken links in the cold chain be prevented? To answer that, here are a few best practices for facilitating good temperatures in transit.

  • Start with appropriate pre-cooling processes. Remove field heat from product as soon as possible, pre-cool containers, and “pulp” or take product temperature to ensure it’s at the correct setpoint.
  • Follow proper loading practices for optimal air circulation.
  • Establish and communicate proper transport temperatures; pay attention to mixed loads.
  • Employ independent temperature-monitoring devices and proper placement procedures.
  • Check temperature history and place immediately into cold storage at the distribution center.

Transport from the distribution center to the retailer needs to be closely monitored as well. In fact, this is one of the areas where we see the most breakdowns: the transfer at the final point of sale. Deliveries typically come in very late and perishables are not put into cold storage quick enough.

Baked bananas and blockchain

One of our customers recently shared a story about a load of bananas they received. The retailer was using one of our real-time monitoring devices and knew before the containers were unloaded that bananas had basically cooked in transit. Armed with real-time temperature data, they declined the shipment, saving $28,000 on two loads — loads they may have previously accepted.

Digital time and temperature loggers, real-time trackers with proactive alerts have been a part of perishable loads in transit for years. As illustrated by the story above, they have been instrumental in identifying temperature flux and allow retailers and suppliers to be more preventive and proactive.

Emerson is leading exciting developments in analytics based on aggregated data from these devices. Vast amounts of in-transit time, location and temperature intelligence are now stored in the cloud — and can be tapped for deeper cold chain insights on best routes, carriers, shipping lanes and suppliers.

Another technology getting a lot of industry buzz is blockchain. (It’s not just for cryptocurrency.) Blockchain offers an incredibly secure platform to share deep and detailed data across all the supply chain players. It lets disparate, previously siloed, entities share common, unalterable data on a common framework. We’re currently working with IBM to create food freshness applications and shelf-life predictors that could be shared across the blockchain platform. And that’s only the beginning.

To hear more best practices, cold chain success stories and even a few cautionary tales, be sure to view the full E360 Forum presentation here.

 

[New E360 Webinar] Best Practices in Enterprise and Facility Optimization

ronchapek_2 Ron Chapek | Director of Product Management

Emerson Commercial & Residential Solutions

In today’s competitive food retail and foodservice markets, empowering your service teams to provide fast, effective issue resolution can be a true differentiator. In our next E360 Webinar, which will take place on Tuesday, Oct. 29 at 2 p.m. EDT/11 a.m. PDT, we will explain how new enterprise management and collaboration tools can help operators optimize their service teams and implement efficient processes across the enterprise.

Supermarket, convenience store and restaurant operators are faced with a perfect storm of facility management and servicing challenges. As the pool of qualified technicians continues to shrink, those entering the service profession have limited systems knowledge and must quickly learn to navigate an increasingly complex landscape of new technologies and architectures. Simply put, operators need new tools to help their service teams:

  • Process and prioritize alarms per specific geographic regions, areas of responsibility and importance to business success (HVAC, refrigeration, ice machines, beer coolers, etc.)
  • Access the information needed to resolve issues quickly and fix equipment failures on the first attempt

In our next E360 Webinar, I’ll be joined by Pranay Shah, senior technical product owner at Emerson, to discuss how new enterprise software and collaborative community platforms can be combined to prioritize, triage and accelerate issue resolution for both internal service teams and supporting contractor networks. As we explore how to leverage these powerful and intuitive tools to streamline facility management and servicing processes, attendees will learn:

  • How enterprise management software can be tailored to end user roles and responsibilities
  • How these tools can be mapped to specific processes per unique business objectives
  • How alerts are filtered and prioritized to address next most important tasks
  • How service networks and communities enable team collaboration, live chat, video and technical knowledge base access

So if you’re ready to learn how to put these tools to work in your organization — and better optimize the service teams and processes with which you manage them — then register now for this informative webinar and make plans to join us on Tuesday, Oct. 29 at 2 p.m. EDT/11 a.m. PDT.

Regulatory Uncertainty Impacts Refrigerant Decisions

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 ACHR The NEWS article about the uncertainty surrounding the dynamic regulations governing the use of refrigerants. The article provided perspectives from several industry stakeholders, and I was happy to discuss Emerson’s views on the short- and long-term implications of the situation. Read a summary of the article below and view it here in its entirety.

For the last two years, the commercial refrigeration industry has been in a period of uncertainty regarding the regulations that govern the use of hydrofluorocarbon (HFC) refrigerants with high global warming potential (GWP). Since the U.S. DC Court of Appeals ruled that the Environmental Protection Agency (EPA) did not have the authority to phase down HFCs, the EPA’s role in the national HFC phase-down has been unclear.

R-22 phase-out is still in effect

For the time being, the EPA’s authority covers only the transition from ozone-depleting substances, such as the chlorofluorocarbon (CFC) R-22. So, even though the HFC rules have been vacated, the EPA still has the authority to phase out R-22, which is scheduled to take place on Jan. 1, 2020.

While there’s plenty of discussion about the fate of HFCs, it would be unwise to presume that the 2020 R-22 phase-out won’t have significant impacts. In fact, it may surprise some to learn that there are still many operators with older refrigeration systems currently charged with R-22. But after Jan. 1, they must either retrofit their systems with lower-GWP refrigerants or continue to recover and reuse R-22 until their supplies run out — with the understanding that the latter choice is not a permanent solution.

HFC phase-down continues in California and other states

The absence of a federal mandate to phase down common HFCs is not deterring California from taking its own steps. Per a recent ruling by the California Air Resources Board (CARB), R-404A and R-507A are no longer allowable in many new commercial refrigeration applications.

California’s regulatory stance is a reminder that a retailer’s geographic location is an important factor in the development of their refrigerant strategy. While California is currently taking the lead on U.S. HFC reductions, there are currently

As retailers evaluate their future refrigerant options, state-specific environmental regulations will factor prominently in their decision processes. For example, operators in California are well aware of the efforts to phase down HFCs and most likely have alternative refrigerant plans in place. These operators are either planning for retrofits or trialing new alternative refrigerant architectures.

Strategies for moving forward

Fortunately for operators, component and equipment manufacturers have continued developing solutions that feature a wide range of lower-GWP refrigerant alternatives. These solutions are helping retailers align their sustainability objectives with their refrigeration architectures, and include the following strategies:

  • Retrofit using lower-GWP HFOs — Moving from R-404A to R-448A or R-449A may require adding compressor cooling and other relatively minor system changes but can help operators preserve their existing system investments. Deploying energy optimization best practices will also help them reduce indirect emissions, which lessens their overall carbon footprint.
  • Transition to a new and/or natural refrigerant system — Natural architectures offer maximum carbon footprint reductions and are considered by many as the only true future-proof solutions available today. These systems can be installed in new locations or in parallel with an existing system, allowing the retailer to slowly transition to the natural solution.

Emerson is continuing to develop a variety of alternative refrigerant solutions designed to help operators and equipment manufacturers reduce their carbon footprints. Regardless of the regulations in your specific region, we’re here to support the commercial refrigeration supply chain as it transitions to lower-GWP refrigerant alternatives.

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