Retrofitting Commercial Refrigeration Systems: A Primer

One of the biggest drains on energy consumption in foodservice is commercial refrigeration. So obviously commercial refrigeration can also become an operation’s biggest savings opportunity. How to do that is the question we’ll try to answer.

For most foodservice operations, switching out their entire refrigeration systems is a non-starter. It’s easy to make energy-saving decisions before equipment is actually installed in a facility. But for existing properties like chain restaurants or K-12 school nutrition programs, they are typically not in a position to switch out their entire refrigeration systems.

This doesn’t mean existing operations don’t have the potential to save, though. When you’ve decided to retrofit an existing refrigeration system there are many paths you can follow. One thing is certain you need a qualified and certified commercial refrigeration company to do the work correctly. Let’s take a look.

Retrofitting for Energy Efficiency

Sometimes the low hanging fruit might be enough to meet efficiency standards. Things like replacing old fluorescent lights with LED. Simply replacing flourescents with LEDs can save you 68-85% energy, they also emit less heat, thus reducing the refrigeration load.

Replacing old cooler or freezer doors with new ones and upgrading door gaskets are also key. These reduce cold air leakage because of better insulation, and are easy fixes for many. Installing newer, more modern compressors, fans and door fans can also help you reach your energy efficiency goals.

For more challenging energy concerns however, there are some new technologies that might help.

VSDs

A VSD, or Variable Speed Drive is a compenent used to control motor speed for compressors and fans. Retrofitting a commercial refrigeration system with VSDs involves adding a VSD to an existing motor to adjust its speed based. Traditional HVAC systems operate at fixed speeds, VSDs however allow motors to operate at varying speeds, which significantly saves energy and reduces operating costs.

Retrofitting Commercial Refrigeration Systems: A Primer

LED Lighting

Upgrading to LEDs with smart controls (occupancy sensors) to reduce heat load and energy use. LEDs use much less electrity and therefore generate less heat, meaning less work for your compressor.

LED lights also have a longer lifespan. An LED light lasts over 50k hours while the traditional flourescents only 7 to 15k hours. LEDs are more resistant and robust than flourescents. They can handle moisture and vibration much more readily that the traditional floursescents.

Always remember to hire an experienced and qualified partner to minimize disruption.

Replace Motors and Drives

Install Electronically Commutated (EC) motors and Variable Frequency Drives (VFDs) on evaporator/condenser fans to match output to demand.

A Variable Frequency Drive (VFD) adjusts the electrical frequency to slow down motors when less cooling is needed. Using them can reduce electricity costs, often 30-50%, by matching output to actual demand. You will also end up with a more quiet operation since they reduce vibration as well.

These measures reduce utility charges at peak hours and reduce cycling for smoohter operatoin and less wear and tear on compressors and fans.

Replacing Doors and Covers

Add doors or night covers to open display cases to drastically cut energy loss. This can dramatically cut energy use by 20-75%. It does this by preventing cold air loss, improving food safety, reducing system strain. Another benefit is creating better customer comfort, as less of that cold air escapes thus creating a ‘cold aisle’ in your store.

Upgrade Compressors

Retrofitting commercial refrigeration with digital compressors can boost efficiency by enabling variable capacity. The variable capacity, precisely matching cooling to demand, reduces energy waste from constant on/off cycling. This can improve temperature control, often achieving significant savings.

Retrofitting commercial refrigeration with digital compressors boosts efficiency by enabling variable capacity. This is done toprecisely match cooling to demand, reducing energy waste from constant on/off cycling, and improving temperature control, often achieving significant savings

Another option is floating head pressure (FHP), which can significantly cutting compressor load and energy use by up to 15-45%. It does this by controlling condenser fans and using advanced controls like EEVs (Electronic Expansion Valves) and LPA (Liquid Pressure Amplifiers), boosting efficiency by letting head pressure drop with ambient temperatures.

Other Options

Refrigerants: Transition to lower Global Warming Potential (GWP) refrigerants. This involves switching to natural refrigerants (like CO2, ammonia, propane) or low-GWP blends (HFOs/HFCs).
Insulation & Gaskets: Improve door seals, insulation, and minimize air infiltration to prevent cold air loss and heat gain.
Controls: Upgrade to electronic controls, advanced sensors, smart thermostats, and occupancy sensors to optimize operation and reduce runtimes.

The Cost

Retrofitting commercial refrigeration for efficiency involves costs for equipment, labor, and potential electrical/piping work, ranging from thousands for smaller upgrades (like VSDs or controls) to tens of thousands or more for major component replacements or chiller retrofits, with typical project costs for larger systems often 10-20% of a new install’s price but yielding significant energy savings (3-7 year payback common) through options like Variable Speed Drives (VSDs), smarter controls, and component upgrades, according to sources like Consulting – Specifying Engineer and R&R Refrigeration.

Smaller upgrades might cost potentially a few thousand dollars, focusing on precise adjustments. Costs for swapping out compressors and fans, etc, etc., can vary, but retrofitting part is is often the lower cost alternative to buying a new unit.

Major retrofits can range from $15,000 to over $50,000. This range depends on whether you need new equipment with major chiller retrofits potentially reaching $500,000+.

In Conclusion

Your busines will greatly benefit from lower utility bills and reduced maintenance costs. There are also substantial environmental reasons to implement these measures, lowering carbon footprint and reducing energy waste.

About International Coolers®

International Coolers® combines premium-quality walk in coolers and walk in freezers with industry expertise. We’re proud to offer custom walk in coolers, walk in freezers, combos, convenience store coolers and freezers that are built to last, designed for efficiency, and that can be shipped nationwide as well as internationally. Contact us and get a quote.

We can provide walk in freezers, walk in coolers, convenience store coolers and freezers and drive in coolers. International Coolers specializes in comprehensive project management, seamlessly handling a diverse range of commercial refrigeration endeavors like food distribution centers, pharmaceutical cold rooms, and processing facilities. We have expertise that spans from initial design and meticulous planning, including architectural blueprints, to the precise engineering drawings necessary for permits, culminating in flawless installation.

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