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Posts tagged ‘Retail Solutions’

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 Management: How Changes to Section 608 Impact Our Industry

JohnWallace_Blog_Image John Wallace | Director of Innovation, Retail Solutions

Emerson Commercial & Residential Solutions

I was recently interviewed for an article in ACHR’s The News magazine, “EPA’s Proposed Changes to Section 608 Cause Concern in the Industry,” where I provided my perspective on the current state of leak detection, repair and other provisions.

Refrigerant leak response and repair regulations have placed our industry in uncertain waters. As you may know, the Environmental Protection Agency (EPA) has proposed a new rule that rescinds some provisions of its Section 608 mandate, affecting equipment with 50 lbs. or more of hydrofluorocarbons (HFCs) or other substitute refrigerants. These best practices were developed in consultation with the HVACR industry to ensure safety, establish proper reclaim and recycling processes, and of course, reduce carbon emissions.

In November 2016, the EPA extended the scope of Section 608 — from refrigerants containing ozone-depleting substances (ODS) to nonexempt substitute refrigerants such as HFCs. Because the Court of Appeals ruled in 2017 that the EPA could not ban HFCs, the agency has decided that it also did not have the authority to regulate these refrigerants under Section 608.

Establishing best practices

Awareness of the importance of leak detection has grown exponentially in recent years. Today, most companies understand that implementing a leak response and repair program is simply a best practice. And for those companies that have already taken steps to comply with Section 608, the vacating of this rule will have little impact.

I stated in the article: “These procedures not only benefit the environment but also help ensure HVACR equipment operates at peak efficiency, including at the lowest overall cost. One of the benefits of the existing regulations has been to raise the awareness of best practices related to HVACR maintenance. Increased awareness generally leads to broader adoption by those in the industry, regardless of whether regulations are in place.”

Simply put, leak detection and repair programs make good sense, regardless of the regulations in place or the type of refrigerant being used. However, with the reversal of Section 608, equipment operators will no longer be under federal mandate to follow these widely adopted refrigerant management best practices:

  • Conducting leak rate calculations when refrigerant is added to an appliance
  • Repairing an appliance that leaks above a threshold leak rate
  • Conducting verification tests on repairs
  • Conducting periodic leak inspections on appliances that exceed the threshold leak rate
  • Reporting to the EPA about chronically leaking appliances
  • Retrofitting or retiring appliances that are not repaired
  • Maintaining related records
  • Overseeing technicians’ use of certified equipment and the reclamation process

These procedures are already considered to be the optimal standard practice, and end users who are focused on operational excellence are likely doing many (or most) of them today.

Maintaining other key program elements

The absence of a federal mandate for responsible HFC management creates a quandary for our industry. Currently, the EPA is seeking comments about the remaining provisions of Section 608, raising concerns about the potential for overturning other benefits of programs — specifically, guidelines for refrigerant reclaim procedures and technician certification and training programs.

Proper refrigerant reclamation reduces the likelihood of introducing impurities, which could lead to premature failures and increased maintenance costs for owners of HVACR equipment. What’s more, the certification program provides the vital information on how to deal with the ever-growing number of refrigerants. As I stated in the article: “One benefit of certification is that wholesalers are able to sell refrigerants to technicians who have a sufficient background and understanding of their liability under the Clean Air Act.”

Path forward

Already, several states are adopting standards for leak detection and control. Again, as I noted in the article, “We are already seeing some states such as California enact regulations that adopt many of the requirements in Section 608. Other states will likely step in, which may create more headaches for the industry. This could create problems for the industry and lead to a patchwork of inconsistent regulations that would be challenging for manufacturers and service providers to navigate.”

As always, Emerson will help you stay informed about further changes to Section 608. Regardless of the regulatory decisions, we’ll continue to provide guidance and expertise on how to design and implement refrigerant management programs.

Top Five Reasons to Choose Copeland Scroll™

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

In an industry era defined by dynamic market forces and regulatory uncertainty, choosing a compression platform as the foundation for your refrigeration equipment is more critical than ever. As supermarket, restaurant and convenience store retailers face unprecedented changes in the way they conduct business, their refrigeration requirements are quickly evolving. Modern systems must meet a variety of emerging challenges, such as:

  • Supporting small- to large-store formats
  • Complying with food safety and environmental regulations
  • Adapting to e-commerce and omnichannel fulfillment requirements
  • Integrating with IoT technologies and building management systems
  • Achieving energy-efficiency and sustainability goals

Whether you’re an OEM updating your product lines, an end user evaluating compressors for new applications, or a technician performing system upgrades and retrofits, the Copeland Scroll compressor platform has the breadth of product lines to meet today’s demanding requirements.

Copeland Scroll has consistently pushed the envelope in refrigeration reliability for decades, and these innovations continue today. Here are the top five reasons leading equipment manufacturers, end users and contractors choose Copeland Scroll to support their refrigeration initiatives:

  1. Widest application and capacity range — When it comes to low- and medium-temperature applications in fractional to large-horsepower capacities from ¾ to 17 HP, only Copeland Scroll meets the full breadth of specifications for today’s diverse applications. In 2019, we’ll add three additional capacities to our popular KA lineup, which recently took home an Innovation Award at the 2018 AHR Expo.

 

  1. Technology leader — Since its introduction, Copeland Scroll has set the standard in compression technology. From digital modulation, liquid- and vapor-injection and low condensing operation to onboard electronic diagnostics and compatibility with low-GWP alternative and natural refrigerants, the Copeland Scroll platform continues to lead the industry in performance- enhancing innovations.

 

  1. Superior reliability and energy-efficiency At the end of the day, what matters most to our customers are reliable performance and energy-efficiency. With 70 percent fewer moving parts and a simple internal suction and discharge method, Copeland Scroll delivers reliable, energy- efficient performance, year after year. Its compact and lightweight design allows it to be integrated in applications where space is limited, without ever sacrificing performance or efficiency.

 

  1. Expert distribution network and support — As the standard in scroll compression technology, Copeland Scroll is backed by a wholesaler network comprised of 850 Copeland-authorized locations with more than 340 certified Copeland technical specialists on staff. And since Copeland Scroll is manufactured in the U.S., when you need customer service, product support or availability, representatives from our American base of operations can quickly deliver the compressor you need.

 

  1. Product development expertise — When you choose Copeland Scroll compressors, you’re also partnering with Emerson and gaining access to our extensive capabilities to support your product development efforts, including: application engineering; design, testing and certification services; innovation center proof-of-concepts; and app development.

 

From transport to cold storage, Copeland Scroll compressors are the first choice in every link of the food supply chain. So, don’t put your company’s reputation at risk. Choose the leader in scroll compression and commercial refrigeration technologies. Choose the proven dependability of Copeland Scroll.

 

Refrigerant Leak Detection and Regulatory Update

JohnWallace_Blog_Image John Wallace | Director of Innovation, Retail Solutions

Emerson Commercial & Residential Solutions

Proper refrigerant leak detection is essential for retailers, potentially saving them thousands of dollars annually and helping to meet regulatory requirements. For the full article, click here.

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Refrigerant leaks can cause both economic and environmental disruptions for retailers. Today, the average supermarket has two to four refrigeration racks charged with approximately 3,500 pounds of refrigerant. According to the Environmental Protection Agency’s (EPA) GreenChill research, about 25 percent (875 pounds) of that refrigerant is lost each year due to leaks. At $7 per pound, this loss equates to an annual expense of about $6,100 — more than $600,000 annually over a chain of 100 stores. And that’s just the financial aspect. In the same 100-store example, nearly 70,000 pounds of refrigerant are leaked into the atmosphere.

Introduced in the 1990s to address emissions of ozone-depleting substances such as chlorofluorocarbon (CFC) and hydrochlorofluorocarbon (HCFC) refrigerants used in stationary refrigeration and air conditioning units, Section 608 of the Clean Air Act was revised in 2016 to include hydrofluorocarbon (HFC) refrigerants. This revision also introduced more stringent requirements for repairing leaks in larger appliances as well as new record keeping, reporting and disposal mandates.

Per the 2016 revision to Section 608, the next iteration of these requirements will take effect on January 1, 2019, and include the following changes:

Lower leak thresholds. The new thresholds are 30 percent (from 35 percent) for industrial process refrigeration (IPR), 20 percent (from 35 percent) for commercial refrigeration equipment (CRE), and 10 percent (from 15 percent) for comfort-cooling equipment.

Required inspection and monitoring. Section 608 now requires quarterly/annual leak inspections or the use of automatic, continuous monitoring devices for refrigeration and air conditioning equipment that have exceeded the threshold leak rate.

 New reporting requirements. Owners and operators must maintain hard or electronic copies of reports documenting the full charges of appliances and the types of automatic leak detection systems used. For chronically leaking appliances, owners/operators must also submit reports if their systems contain 50 or more pounds of refrigerant and leak 125 percent or more of their full charge in one calendar year.

 Disposal requirements. Technicians must keep a record of refrigerant recovered during system disposal from systems with charge sizes ranging from 5 to 50 pounds.

With all of these revisions on the horizon, it’s important to note that the EPA takes enforcement very seriously. The consequence of noncompliance can be significant: the agency is authorized to assess fines of $37,500 per day for violations.

We recommend that companies implement effective refrigerant leak detection programs to minimize refrigerant leaks and plan a response strategy in the event of a leak. Direct leak detection technology includes fixed or portable monitors installed on-site, which detect the concentration of refrigerants in the air. These can be set close to the anticipated leak airstream, in enclosed spaces and in areas near the floor where leaked refrigerants collect.

 The renewed regulatory focus on reducing refrigerant leaks has caused retailers to put more emphasis on developing efficient and effective leak detection strategies. Leak detection programs not only allow retailers to stay on top of regulations; they can potentially save costs associated with lost refrigerant, the degradation of refrigerated system performance and food loss.

Refrigerant Leak Detection Technology Saves $$ and the Environment

I recently wrote an article featured in Contracting Business discussing the importance of refrigerant leak detection as an essential service for retailers and HVACR contractors.

Refrigerant leaks have long been viewed as an inevitable part of operating a retail refrigeration system.  Retailers often wrote these leaks off as the cost of doing business, but the impact of refrigerant leaks goes beyond what most may expect. The true costs of refrigerant leaks are often underestimated, and contractors who understand this impact will be more valuable partners for their clients.

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According to the EPA’s GreenChill research, the average supermarket loses about 25 percent — or about 875 pounds — of its refrigerant supply because of leaks. When you multiply this across many stores in a grocery chain, the costs can be significant — not only in terms of the cost of the refrigerant, but with associated labor costs. There is also a potential loss of business because of food disruptions and food quality issues that may arise.

Refrigerant leaks also have an environmental impact. Most commonly used refrigerants are greenhouse gases and some are ozone-depleting substances. Assuming a leak rate of 20 percent across a chain of 100 typical supermarket stores, the amount of refrigerant leaked annually is equivalent to the emissions of 24,000 cars or 10,600 homes.

The EPA has had regulations in place for a number of years as part of the Clean Air Act. Now, the EPA has proposed an update to those regulations governing most refrigerants that could impact both contractors and retail operators. Contractors who keep up with how these regulations are changing can be better retailer partners by aligning their services to meet these changes. An effective leak detection program can help retailers manage and properly repair refrigerant leaks and avoid costly EPA settlements.

The goal should be not only to establish proper leak detection response protocols, but also to institute proactive measures that minimize or eliminate leaks altogether. A zero-tolerance policy for leaks is ideal. Accurate detection methods, reliable notifications and continuous monitoring are the key elements needed for effective leak detection programs.

To learn more about refrigerant leak detection for contractors, read the full Contracting Business article here.

 For more than 20 years, Emerson Retail Solutions has been helping businesses like yours safeguard food, reduce energy consumption, protect the environment and optimize business results. To learn more about our technology solutions and services for retailers, visit our website.

 John Wallace
Director of Innovation
Emerson Climate Technologies Retail Solutions

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