Manufacturer of temperature-controlled display cases, Structural Concepts, has achieved a 53 per cent energy saving by migrating its product portfolio to natural refrigerant R290 and variable speed technology.
Structural Concepts transitioned its entire portfolio of refrigerated food displays, going from fixed-speed compressors using HFO refrigerants (R449A and R513A) to Embraco UFMFT condensing units equipped with dual voltage variable-speed compressors, using R290 natural refrigerant.
The impressive case study results were presented at the ATMOsphere America Summit 2024.
Nidec Global Appliance brand, Embraco, and Structural Concepts, monitored the migration behaviour in two applications to compare with the previous configuration: a small food display using a single compressor and a larger capacity display using two compressors.
The first one, an under-the-counter application, with one refrigeration circuit using less than 150 grams of R290, achieved 53 per cent savings in energy consumption and a 55 per cent reduction in Total Equivalent Warming Impact (TEWI).
The second application, an upright grab-and-go display case, with two refrigeration circuits (each with less than 150 grams of R290), delivered an 11 per cent drop in energy consumption and a 17 per cent decrease in TEWI.
Additionally, a third set of testing was carried out with a 1,20 x 2,40 meters (4x8 feet) horizontal display case, designed with two refrigeration circuits, with R290 and variable speed compressors, operating independently.
After installing the recently launched Embraco Sync Controller, designed to manage multiple refrigeration circuits together, it resulted in a 12 per cent energy saving.
Nidec Global Appliance application engineer for the North America region, Johari Gregorio, said the Embraco Sync is one of the solutions that compose the Sync it All portfolio, along with the Embraco AIR fan, the YouControl development interface, and Embraco variable-speed compressors.
“The test demonstrated the effectiveness of the new controller in enhancing energy efficiency and temperature stability, for being a component developed specifically to work in synchrony with two Embraco variable-speed compressors,” he said.
Gregorio said the UFMFT model has a reduced size, around 25 centimetres tall (10 inches), which means it fits in all cabinets, allowing more space for the products in the display.
“Additionally, it has a drain pan designed with pipes, which connects to multiple drain pans and equalizes the condensate water among them, resulting in a relevant water holding capacity, around 4.9 litres (1.3 gallons) for each drain pan,” he added.
“Refrigeration equipment manufacturers for food retail, such as Structural, can greatly benefit from buying the complete condensing unit ready to install into their applications, instead of buying and assembling multiple parts.
“It saves time and effort and allows them to focus on their core business, customised food display.”
Structural’s senior engineering manager, Rob Dody, said the migration also positively impacted Structural’s manufacturing process, because it reduced the complexity of their compressors inventory.
Dody said that previously the company had 38 different compressor models which was due to the need for different refrigerants and voltages.
“Now we rely on just two Embraco condensing unit models, equipped with dual voltage R290 variable-speed compressors, that can serve our whole range of refrigerated merchandisers,” Dody said.
The United States has announced plans to limit the Global Warming Potential (GWP) of commercial food refrigeration equipment to 150 from January, 2025.
The shift to R290 allows Structural Concepts to comply with the new regulations well before the upcoming deadline.
Dody said the overall portfolio migration is estimated to reduce Structural’s TEWI by 33 per cent on average, significantly lowering CO2 emissions.
“Migrating to variable-speed technology and natural refrigerant has enabled Structural to offer more efficient and environmentally sustainable products, aligned with customer expectations and market demands,” Dody said.
Embraco is part of Nidec Global Appliance which has 10,000 employees across nine countries.