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Posts tagged ‘Refrigeration’

Six Steps to a Successful Refrigeration Retrofit

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

Emerson Commercial & Residential Solutions

This blog summarizes an article from ACHR NEWS, entitled “Refrigeration Retrofits Offer ‘Cool’ Savings for Supermarkets.” Click here to read the article in its entirety.

The commercial refrigeration system is the biggest energy user in supermarkets, accounting for about 40 to 60 percent of electricity consumption, according to the Environmental Protection Agency (EPA). For food retailers, getting energy consumption under control is a top priority, and the refrigeration industry has stepped in with new, higher-efficiency equipment and technologies, such as advanced monitoring and control via the internet of things (IoT). However, for many retailers, virtually all their equipment is aging, and buying new equipment and systems across the board would be prohibitively expensive. But there is another path to saving a considerable amount of energy: targeted retrofits or upgrades to their existing systems.

Some energy-saving modifications can be simple and obvious, such as adding doors to cases. But at a recent Emerson E360 Forum, I explained how a systematic approach to retrofits and upgrades can identify savings throughout a store’s entire refrigeration infrastructure, particularly older, energy-demanding direct expansion (DX) centralized systems. It is a six-step process that reveals the primary causes of energy loss and, step by step, proposes energy-saving retrofits and upgrades to your system that can systematically reduce energy costs without breaking the bank.

  1. Conduct a baseline energy audit throughout the store by installing energy-monitoring equipment. These sensors help you analyze the existing energy signature of the entire store before you make any adjustments or retrofits, and will also be invaluable for future temperature monitoring and control to ensure food safety and quality.
  2. Recommission your existing equipment to factory specifications. This may include adjusting setpoints, superheat, suction pressure and other settings. In the process, any broken components can be repaired. This one step alone can result in energy savings of 18 percent or more.
  3. Upgrade your refrigeration technologies. One effective upgrade is changing discus compressors to digital compressors. This single retrofit can reduce compressor cycling, increase system reliability, and improve energy efficiency by 16 percent or more. Installing variable-frequency drives on condenser fan motors can save even more.
  4. Upgrade your HVAC system. Ambient store temperatures are major stressors on refrigeration systems. Consider upgrading rooftop units and adding demand-controlled ventilation and humidity controls. Integrating the rooftop units with the refrigeration system in the store is another option, creating a self-contained ecosystem that balances ambient and refrigeration temperatures for significant energy savings.
  5. Upgrade lighting and other renewables. Adding modern lighting technology lowers temperatures. Installing doors onto units lowers energy losses. Electronic case controls and expansion valves (EEVs) fine-tune equipment temperatures, while upgrading to electronically commutated (EC) motors lowers electricity consumption while improving equipment efficiency.
  6. Perform condition-based maintenance. Once you’ve migrated to these capital upgrades, it’s important to step up your regular maintenance intervals to continue your gains in efficiency and cost savings.

With these targeted retrofits and upgrades, you can systematically make your centralized DX system more effective in maintaining food quality and safety while simultaneously uncovering efficiencies that can result in significant savings.

Smaller Supermarket Formats Dictate Fresh Refrigeration Approaches

JohnWallace_Blog_Image John Wallace | Director of Innovation, Retail Solutions

Emerson Commercial & Residential Solutions

Meeting the demands of emergent small-format supermarkets requires a new approach to — or adaption of existing — refrigeration architectures. This blog is based on a recent article that discusses available options. Read the full article here.

One of the biggest trends shaping the food retail industry is the shrinking store footprint. Instead of building large mega centers that once dominated the landscape, today’s retailers are opting to extend their brands into smaller stores, typically in densely populated areas. The small-format trend is part of a larger evolution — one that emphasizes high-quality, fresh, perishable offerings while appealing to consumer desire for more convenience.

Food retailers that are embracing these changes must also evaluate how their approaches to refrigeration architectures and controls will also need to adapt. Fortunately, there is no shortage of available options to help operators make this transition.

Scale down for “centralized” familiarity
A traditional big-box supermarket has more than 100 cases (a mix of medium- and low-temperature cases) supported by centralized refrigeration racks and controls designed to optimize large systems of this type. If you shrink these systems down for smaller formats with less merchandise, it stands to reason that you may not need as many racks. With stores shrinking from more than 100,000 to less than 20,000 square feet, they simply won’t need the same refrigeration horsepower.

In many cases, operators may still want to use centralized architectures for both medium- and low-temperature cases, but appropriately scaled down to suit the small format. Often, we’re able to design a system with one rack to manage medium- and low-temperature needs. Since it’s a much smaller centralized system to support fewer case lineups, it has much shorter refrigeration lines running out to the cases.

From a system controls standpoint, this smaller centralized architecture isn’t drastically different, so retailers can achieve relatively the same look and feel in both large and small store formats — while also providing the flexibility to scale across the full spectrum of store sizes.

Explore “distributed” efficiencies

While distributed refrigeration systems have been preferred in large supermarkets in Europe and other global regions, they are also well-suited for the small-format emergence in the U.S. Distributed architectures come in different formats and offer a cost-effective refrigeration strategy for smaller stores. Preferred distributed architectures include:

  • “Self-contained” cases (i.e., a completely integrated refrigeration system within the case); also provide spot-merchandizing flexibility
  • Modular refrigeration systems capable of supporting small lines of cases sharing similar characteristics

Distributed architectures also have a greater impact on the way controls are set up and utilized. In a distributed scenario, electronic controllers are installed at the refrigeration cases. Additional sensors are typically required to capture data, allow for better control, and support remote troubleshooting activities.

Standardize your footprint

When adding smaller-format stores to an enterprise network, it may not be in your best interest to introduce a completely new refrigeration and controls platform. For retailers with multi-site networks of large- and small-format stores, it’s especially important to select refrigeration architectures and control platforms that provide a standardized view.

When evaluating refrigeration options, look for platforms that support the evolution of internet of things (IoT) in refrigeration and facility management. These systems represent the next generation of operational efficiencies by offering cloud connectivity, predictive maintenance and advanced multi-site management software.

 

Refrigerant Regulations: 2018 Recap and 2019 Impacts

RajanRajendran2 Rajan Rajendran | V.P., System Innovation Center and Sustainability

Emerson Commercial & Residential Solutions

The year 2018 brought many changes to refrigerant regulations, with additional activity expected in 2019 and beyond. This blog highlights some of the key developments, which were presented in a recent E360 article. Read the full article here.

 

The regulation of refrigerants continues to be a source of great uncertainty in the commercial refrigeration industry. As global, national and state regulations have targeted the phase-down of hydrofluorocarbon (HFC) refrigerants in recent years, some in the industry have begun the transition toward alternative refrigerants with lower global warming potential (GWP). But these environmentally friendly options raise additional questions about performance and safety.

All in all, it’s a complex regulatory mix that got even more complicated in 2018. But we’re here to recap recent events and place them into a larger context.

The status of EPA SNAP Rule 20

In 2017, the U.S. District Court of Appeals for the D.C. Circuit ruled to vacate the Environmental Protection Agency’s (EPA) Significant New Alternative Policy (SNAP) Rule 20. The court ruled that the EPA did not have authority to phase down HFCs under the Clean Air Act (CAA) — which was originally intended to eliminate ozone-depleting substances (ODS) — and thus could no longer enforce its 2015 GWP-based mandates.

In the absence of Rule 20, the commercial refrigeration industry has many questions about what the path toward a more sustainable and environmentally friendly future for refrigerants will look like. Industry calls to overturn the District of Columbia Court of Appeal’s decision were declined by the Supreme Court, which stated it would not hear the HFC case1. Currently, the EPA is drafting new regulations that will clarify its plans to move forward with SNAP. We anticipate details on their position early this year.

EPA rescinds other HFC-related regulations

The EPA has also indicated that it will no longer enforce refrigerant delistings and has proposed to roll back other HFC-related regulations2. In particular, the EPA has proposed excluding HFCs from the leak repair and maintenance requirements for stationary refrigeration equipment, otherwise known as Section 608 of the CAA.

California adopts Rule 20 as the basis for its initiatives

Regulatory uncertainty at the federal level is not preventing states from adopting their own refrigerant regulations and programs. California Senate Bill 1383, aka the Super Pollutant Reduction Act, was passed in 2016 and requires that Californians reduce F-gas emissions (including HFCs) by 40 percent by 20303. The California Air Resources Board (CARB) has been tasked with meeting these reductions.

Since 2016, CARB had been using EPA SNAP Rules 20 and 21 as the bases of its HFC phase-down initiatives. Even after SNAP Rule 20 was vacated, CARB moved to adopt compliance dates that were already implemented or upcoming. The passing of California Senate Bill 1013 — aka the California Cooling Act — in Sept. 20184 mandates the full adoption of SNAP Rules 20 and 21 as they read on Jan. 3, 2017. The law is currently in effect and does not require additional CARB rulemaking to uphold compliance dates.

CARB is also proposing an aggressive second phase of rulemaking that would further impact commercial refrigeration and AC applications. CARB has held public workshops and invited industry stakeholders to comment on the details of this proposal.

Meanwhile, many other states have announced their plans to follow California’s lead on HFC phase-downs. The U.S. Climate Alliance, formed in 2017 out of a coalition of 16 states and Puerto Rico, is committed to reducing short-lived climate pollutants (SLCPs), including HFCs. Among these alliance states, New York, Maryland, Connecticut and Delaware have announced plans to follow California’s lead on HFC phase-downs.

Refrigerant safety standards and codes under review

Many of the low-GWP, hyrdrofluoroolefin (HFO) refrigerants are classified as A2L, or mildly flammable. R-290 (propane) is also becoming a natural refrigerant option for many low-charge, self-contained applications. Currently, national and global governing agencies are evaluating the standards that establish allowable charge limits and the safe use of these A2L and A3 refrigerants.

Internationally, the International Electrotechnical Commission (IEC) has proposed increasing charge limits for refrigeration systems in IEC60335-2-89 as follows:

  • A2Ls — from 150g to 1.2kg
  • A3s — 500g for factory-sealed systems, and will remain at 150g for split systems

These proposals are still under review and will likely be published sometime in 2019.

Kigali Amendment took effect on Jan. 1

The regulatory uncertainty in the U.S. can sometimes obscure international efforts underway to phase down HFCs. The Montreal Protocol has led the way on this effort for nearly a decade5. In 2016, 197 countries met in Kigali, Rwanda, and agreed on a global HFC phase-down proposal. Known as the Kigali Amendment, this treaty has been ratified by 53 countries (including the E.U.) and took effect on Jan. 1 for participating countries. The U.S. is still considering ratification.

As we move into 2019, there are many moving pieces on the regulatory chess board, but also some encouraging signs of progress. We will be providing the very latest regulatory updates in our next E360 Webinar. Register now to stay informed.

  1. https://www.achrnews.com/articles/140040-supreme-court-declines-to-hear-hfc-case
  2. https://www.epa.gov/section608/revised-section-608-refrigerant-management-regulations
  3. https://leginfo.legislature.ca.gov/faces/billNavClient.xhtml?bill_id=201520160SB1383
  4. https://leginfo.legislature.ca.gov/faces/billNavClient.xhtml?bill_id=201720180SB1013
  5. https://en.wikipedia.org/wiki/Montreal_Protocol#Hydrochlorofluorocarbons_(HCFCs)_Phase-out_Management_Plan_(HPMP)

Trends Impacting the Supermarket Refrigeration Landscape

JasonBorn_Blog_Image Jason Born | Innovation Lead, The Helix
Emerson Commercial & Residential Solutions

During our E360 Forum last year in Houston, I led a Q&A panel discussion on the trends and market forces impacting the refrigeration landscape in food retail. Sharing their thoughts and insights were industry experts Derek Gosselin, director, technical product support, Hillphoenix; and Brad Thrasher, south central regional sales manager, Zero Zone. Below are some of their views on key trends; view the full E360 Forum presentation.

The Changing Face of Food Retail

Thirsty from wandering the aisles of your local grocery megamart? How about a craft beer break? Or maybe shopping for food just makes you hungry. Grocery shoppers today can virtually eat their way around the world as in-store food bazaars offer freshly prepared ethnic fare: Mexican “street food”, noodle bowls and wood-fired pizza. No time to shop? There’s always curbside pick-up of weekly grocery staples on your way home from work — just click and collect. And today, going small has never been bigger, with millennials and Generation Z flocking to urban areas and higher-density living. It’s no surprise that smaller-footprint grocery and food specialty stores are popping up in mixed-use buildings that were never intended to support things like complex refrigeration or HVAC systems.

Yes, the face of food retail is changing. And with this change comes a host of new opportunities (and challenges) for commercial refrigeration. I’ve summarized some of the key takeaways from this informative question and answer session.

On e-commerce, omnichannel and digital shopping

The first topic of discussion was the impact of the digital shopping trend. Today, more consumers are shopping for groceries online. I asked the panelists how brick-and-mortar retailers were responding.

Thrasher: I’ve seen some reports (FMI-Nielsen) that say that online grocery sales could grab up to 20 percent of the market. That seems pretty aggressive to me. But it’s definitely a rising trend. Traditional food retailers are responding by adding services like curbside pick-up. They are making home deliveries. You have to adapt to whatever direction the market is going.

Gosselin: For the retailers, it’s about what identifies them as different. Amazon is driving sales directly online. What can you offer to differentiate yourself, not only from online shopping, but the competition in your marketplace? Many stores have found success creating destination centers within their produce and other perimeter departments: food preparations, beer and wine tastings, restaurants, meals-to-go programs. That’s where the trends are going to be. And, of particular interest to everyone here: How do make sure you have appropriate refrigeration at these dynamic destination centers so that they can control your food quality and get it efficiently distributed?

On Click & Collect

Building on the idea of curbside service, I asked our panelists about the grocery pick-up lockers that are popping up everywhere and what that might mean for the future.

Gosselin: If you’re going to offer perishables as part of your curbside pick-up, you’re going to need to incorporate refrigeration. And it’s not just with in-store Click & Collect programs. I’ve also seen trends where retailers will place a portable refrigerated unit on your porch, so when they deliver fresh food or frozen items, they have a convenient and appropriately refrigerated location. Most consumers are probably not going to give you the key to their home.

Thrasher: Many stores are looking at self-contained or hybrid systems. Future refrigeration will need to be more flexible so that retailers can expand quickly and easily. If your curbside (pick-up) starts minimally but grows quickly, you’ll want a flexible, easy-to-implement solution so you can move quickly to serve customer demand.

Curbside pick-up is a relatively recent phenomenon. To add it as service, you have to dedicate and adapt more space in your store. But that doesn’t come without cost and questions. As we all know, for everything new you add in-store, something else will probably need to come out.

On the future

Before jumping into an audience Q&A, I asked the panelists how their retailers are dealing with change and some of the main factors driving their refrigeration decisions.

Thrasher: No one knows with certainty where the future will go. Some decisions will continue to be informed by technology and regulatory changes. And, certainly, costs always play a critical role. With refrigerants, for example, as regulations come, they may eliminate possibilities. It’s hard to go “all in” into a refrigerant when it could eventually be obsoleted, driving costs up for replacements. The same concept applies to system architectures.

Gosselin: How do you get in front of change? Do you go micro-distributed? Do you use natural refrigerants? What technologies will be developed in answer to changing rules?

For the end user, the challenge is not only what do they have to do to maintain their current fleet of stores, but what are they going to do for future stores so that they don’t add to the problems? And then how do they do that under a cost-effective and compliant refrigerant management program?

Thrasher: The bottom line is that there’s simply no one solution for everyone. Every retailer has a different set of objectives and challenges, influenced by regulations, technology and costs, but ultimately driven by the evolving needs of the markets they serve.

To take a deeper dive into our discussion, be sure to watch the full E360 Forum session.

 

Copeland Hermetic CS Compressors Rated for Lower-GWP Refrigerants

VarunGarg_Blog_Image Varun Garg | Manager, Product Management – Refrigeration

Emerson Commercial & Residential Solutions

The Copeland™ Hermetic CS compressor line has been extended for use with leading alternative refrigerants. To learn more about this important update, read our recent E360 product spotlight.

Copeland Hermetic CS compressors are commonly used in self-contained and remote walk-in coolers, as well as in ice, soft serve and frozen carbonated beverage applications. Most recently, we’ve updated this industry-standard compressor platform to qualify for use with modern refrigerant alternatives — which include R-407A, R-448A and R-449A — to offer lower glower warming potential (GWP) while providing the same reliable performance.

Found in a wide range of commercial refrigeration applications, R-404A is one of the most commonly used hydrofluorocarbon (HFC) refrigerants. In recent years, HFCs like R-404A have been targeted for phase-down via global, federal and state regulatory efforts to limit the use of high-GWP refrigerants. Throughout the industry, many operators are actively seeking lower-GWP options to help them achieve regulatory compliance and meet corporate sustainability initiatives.

Many factors must be taken into account when considering how to transition to a lower-GWP alternative refrigerant, including service, maintenance and operational requirements. It’s no surprise that many operators are hesitant to transition to an option that will force them to overhaul their current refrigeration architecture or introduce a new compression platform. Emerson is helping those familiar with the Copeland Hermetic CS compressor line move from R-404A to one of these approved alternatives — without introducing new system complexities.

For those seeking to comply with regulatory targets or meet sustainability objectives, Copeland Hermetic CS compressors are qualified to use R-407A, R-448A and R-449A in medium-temperature applications. This will enable significant GWP reductions compared to R-404A.

R-404A 3,922 GWP
R-407A 2,107 GWP
R-448A 1,273 GWP
R-449A 1,282 GWP

GWP by refrigerant

Retrofit vs. new: considerations
With these new refrigerant qualifications, operators now have the option to retrofit their legacy Copeland Hermetic CS compressors. It’s important to understand that R-407A, R-448A and R-449A are not considered true “drop-in” replacements.

Even though operators can keep the same compression platform, switching from R-404A to one of these lower-GWP options requires adherence to Emerson’s Refrigerant Changeover Guidelines to help ensure optimum system performance. Expansion valve adjustments, proper lubrication and filter changes must be followed per the application engineering bulletin.

For new applications, this newly qualified Copeland Hermetic CS line of compressors grants operators the flexibility of determining which replacement options are best suited to meet their external regulatory requirements and/or internal sustainability initiatives. Emerson recommends consulting its application engineering bulletin or a certified compression expert to help better understand the performance characteristics of each low-GWP refrigerant option.

To learn specific performance ratings of these new refrigerants, please visit the Copeland Online Product Information (OPI) tool. R-448A and R-449A data will be published in February 2019.

 

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