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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.

Supermarket Upgrades That Impact Energy Efficiency and Cost Savings

DarrenCooper Darren Cooper | President

Renteknik Group

At the E360 Forum in Houston last fall, Nik Rasskazovskiy, director of business development for ClearFlow Energy Finance, and I discussed the role of energy services companies (ESCOs) in helping grocery operators achieve and sustain long-term energy savings with end-to-end solutions. We shared our insights and experiences, as well as best practices and real-world case studies. Read more below, then view the full E360 Forum presentation.

According to Progressive Grocer Magazine, food retail is an almost $700 billion industry. Operating on razor-thin margins (generally a little more than 1 percent and only seeming to get slimmer every year), the industry is always on the lookout for new ways to cut costs and boost profitability.

Already making a considerable positive impact on the bottom line in other industries, ESCOs can offer grocery operators a new opportunity to reduce their energy spend — and increase profits.

Reducing energy spend is already a key objective for supermarket operators. ESCOs offer a systematic way to implement sustainable, long-term efficiency plans across their fleet with minimal risk or initial out-of-pocket expense.

How does it work?

ESCOs are in the business of developing, designing, funding and ultimately building turnkey solutions that save energy, reduce energy costs, and decrease operations and maintenance costs at their customers’ facilities.

ESCOs actually guarantee their clients a specific level of energy cost savings from the proposed project. They are subsequently compensated via the actual performance of the project, earning a percentage of the overall energy savings dollars for an agreed upon length of time. At the end of the term, the client keeps the savings for perpetuity.

In the presentation, I said, “The opportunities are real and the savings are real. We’re not doing anything that is really groundbreaking. This is not new technology. This is proven technology that you can actually utilize and implement in your systems. The ESCO part means that there’s no upfront cash necessary. We’re now in a position to provide this as a turnkey solution. We can work with your preferred equipment supplier and your preferred contractor, without needing any money, so you’re cash flow positive from day one.” And I meant every word of it.

The first step in your journey to energy efficiency: establishing a baseline

To identify savings opportunities, you must first fully understand your current energy consumption. Fortunately, today’s device-level power monitoring technologies offer real-time insights into your control systems and can help create “power profiles” by tracking usage across a wide range of temperatures and conditions.

Beginning from that baseline, the ESCO team works with food retailers to conduct comprehensive building and systems audits to identify opportunities for sustainable, long-term energy efficiency upgrades. This can take the form of refrigeration upgrades, variable frequency drives (VFDs), new cases or case controls, HVAC and demand control ventilation, and even renewable technologies if they make sense.

A proven process that’s yielded positive results, the ESCO methodology is sound and straightforward:

  • Building system audit completed — opportunities identified, target savings established
  • Client and ESCO enter into guaranteed, performance-based energy savings performance contract
  • ESCO secures financing
  • Project is built and commissioned
  • Ongoing monitoring and verification ensure that target efficiency savings are being met
  • Lender is repaid from savings
  • At the end of the term, the client keeps all savings

“It’s really a win-win situation,” noted Rasskazovskiy, who’s successfully navigated the financial end of projects across multiple industries. “Once the ESCO organizes everything, implements the project and the savings start trickling in, there’s a management process that verifies that the actual savings have been achieved. Those savings are shared between the end customer and the ESCO to pay out all the services costs, including financing. After the term of the contract is done, the customer is left with the same equipment and gets to enjoy 100 percent of the savings going forward.”

To learn more about ESCOs and the retail food industry, including real-world savings examples, watch the video here.

 

How to Create the Perfect Climate in Supermarkets

ronchapek_2 Ron Chapek | Director of Product Management/Enterprise Software

Emerson Commercial & Residential Solutions

I recently participated in an article for Winsight Grocery Business, which discussed the importance of keeping refrigeration and HVAC systems in harmony. Click here to read the full article.

How to Create the Perfect Climate in Supermarkets

Refrigeration and HVAC costs are among the biggest operational expenses a supermarket faces. The reasons? People create warmth. Refrigeration creates cold. Humidity creates wetness. And in supermarkets, HVAC systems constantly struggle to maintain the right temperature and humidity for people, equipment and products. With proper management and planning, supermarket operators can balance these factors and even optimize HVAC and refrigeration systems to work in coordination with each other.

 The battle between HVAC and refrigeration

In most buildings, the job of an HVAC system is to maintain a comfortable indoor temperature for customers and staff. But HVAC systems face unique challenges in supermarkets. Coolers, refrigerated display cases, freezers and other units (particularly those without doors), pour cool, dry air into stores. This isolated cold air stresses HVAC systems year-round, as they have to increase heating during winter — burning a lot of energy — while leaving uncomfortably cold spots, even in summer. Your refrigeration equipment alters an HVAC load in ways most systems aren’t designed to handle.

Adding doors or replacing open units can reduce both the load and energy costs. But adding doors creates a different problem: they often fog up — which forces shoppers to open the doors to see what’s inside — defeating the whole purpose of having a door. Fog and frost occur when humid weather, steamy shoppers and chilly air collide.

A foggy situation

Door fogging is a symptom of a very tricky problem: keeping in-store relative humidity (RH) at the proper percentage. If humidity is too high, doors fog over and cooling coils frost up, forcing units to overwork. If the humidity gets even higher, water can condense on floors, walls and even dry-goods packaging. But if the RH is too low, the overly dry air can shorten the shelf life of fresh produce or wilt it.

Moisture, relatively

Almost all the humidity inside a store comes from moister outside air, and it’s up to HVAC systems to lower that humidity to a slightly dry 45 percent RH — and that’s not easy.

The simplest way to do this is to super-chill incoming outside air, because as air cools, its humidity drops. But this wastes energy in two ways: it increases the refrigeration load on the HVAC and can chill the entire store. So, the air first has to be reheated before entering the store, producing yet another energy expense.

Another option to use a desiccant system in the HVAC unit to remove moisture. These systems are effective and reliable, but they require a lot of energy, especially for large spaces like supermarkets.

Harvest-free heat

The article describes a simpler, cheaper solution. The compressors on your refrigeration equipment generate a lot of heat as they compress refrigerants. This excessive heat is usually vented outside the building, wasting a source of free heat. Today, systems can recycle, treat and mix this hot air to create ideal store temperatures and RH — at much lower overall costs.

Advanced systems harvest excess hot air in various ways. Some use the hot vented air instead of the HVAC heater to reheat super-cooled, dehumidified air and reduce reheating costs. Some systems use heat exchangers to recycle the vented hot air to heat a supermarket during cold weather. “Single-path” systems super-chill a limited volume of humid outside air to dry it, then mix it with uncooled air to produce just the right temperature/RH mix. Another system uses two cooling coils, one to cool the hot air as it’s being vented outside, so it can mix with outside air to reach optimal temperature and RH. The incoming air needs little heating or cooling as it reaches the second coil, which greatly reduces the workload on the HVAC system.

Instead of adding to your HVAC system’s workload, your refrigeration equipment can actually help reduce the load, lower your costs, and create the ideal climate for shoppers, employees and facility managers.

 

New Research: The Six S’s of Supermarket Refrigeration System Selection Criteria

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

Emerson Commercial & Residential Solutions

Emerson recently completed a research study of leading food retailers to better understand their refrigeration system selection criteria. This blog is a synopsis of those findings.

Copeland

For several years, we’ve seen an evolution of the traditional supermarket concept, driven by a convergence of multiple market influences which include:

  • The migration to urban areas
  • Smaller store footprints
  • Renewed focuses on safety and freshness
  • Greater need for merchandising flexibility
  • The proliferation of omnichannel fulfillment models
  • The lack of qualified service technicians
  • Energy-efficiency goals and sustainability initiatives
  • The internet of things (IoT)
  • Ongoing regulatory uncertainty

Amidst these many changes, refrigeration systems have also evolved to align with modern supermarket operator preferences. To better understand how these preferences are impacting selection criteria, we recently completed a research study of several leading food retailers. We asked them which factors they feel are the most important when considering the implementation of new refrigeration systems.

We compiled results into six key categories, which we refer to as the six S’s of selection criteria. The following is a summary of those findings:

  1. Simple — Operators are seeking to minimize complexities by using systems that are easy to understand and diagnose. Many associate system simplicity with reliability and believe it can be achieved with fewer moving parts, traditional system architectures and proven refrigeration strategies.
  2. Serviceable — Technician familiarity is important to facilitate ease of service and maintenance activities, and to ensure the availability of parts and refrigerants. Engine rooms should be located away from customers and be relatively easy to access.
  3. Secure — Maintaining customer, employee and technician safety while preserving food quality and safety are always top priorities. With many operators now integrating IoT technologies for more effective facility and enterprise management, securing proprietary operational data is also critically important. Operators seek system architectures that can address these multifaceted safety and security concerns.
  4. Stable — Grocers consistently cite system stability and reliability as primary selection criteria. Systems should be capable of maintaining consistent temperatures, delivering predictable performance, and working according to design specifications.
  5. Smart Electronic controls, system connectivity and integration with facility management services via IoT are becoming more important to modern supermarket operators. They’re evaluating self-monitoring systems that give store managers immediate access to issues, allowing them to take prompt actions to protect shoppers, preserve their brands and prevent unnecessary service calls.
  6. Sustainable — For those supermarket operators driven by corporate sustainability objectives or regional regulatory requirements, the push toward lower-GWP refrigeration strategies is continuing in earnest. Sustainability also speaks to the long-term economic viability of the refrigeration selection, as operators must factor in the total cost of ownership throughout the lifecycle. Reducing energy consumption to minimize operating costs is a concern shared by all.

As refrigeration technologies evolve in response to changing market dynamics, look for emerging system architectures that align with these selection criteria. Emerson is addressing the six S’s of supermarket operator concerns by innovating new systems that blend pieces of proven architectures — borrowing from what has worked in the past and improving upon existing technologies. Stay tuned for more information on these new system strategies in the months to come.

Nine Reasons to Switch to a Variable-Capacity, Digitally Modulated Compressor

In the foodservice, supermarket and transport industries, operators have varying options to attempt to overcome the hundreds of start/stop cycles a compressor can go through to produce the necessary refrigeration load on a typical day. Uneven rack systems still result in high cycling rates and do not offer the desired temperature precision. Hot gas-bypass systems are not energy efficient and are often unreliable. Even variable-speed technology, while an effective form of capacity modulation, is cost prohibitive, especially when replacement costs are considered.

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