Refrigeration Systems: The Hidden Costs

Your refrigeration system seems to be humming along nicely and you’ve got a regular maintenance plan in place. That means you’re cool, right? The truth is there may be hidden sources of system energy waste putting the heat on your operating budget.

Fixed Defrosting

As the evaporator ices up, its capacity decreases, reducing system efficiency. Defrosting on a fixed time schedule is often wasteful. When needed, open the hot gas solenoid only long enough to clear the coil—typically eight to ten minutes.

Heat From Lighting

Traditional incandescent and even fluorescent lighting in walk-in coolers and freezers add heat that must be removed. High-efficiency LEDs last longer and give off less heat than conventional bulbs, and they operate well in cold temperatures.

Short Cycling Compressors

Oversized fixed speed compressors often run at full load for short periods, wasting energy and causing equipment wear and tear. Add variable frequency drives to compressor and fan motors to match output with the load.

Food Waste

Poorly performing refrigeration systems shorten the shelf life of food products. In coolers, the right temperature balance is necessary to ensure safety and food integrity. Regularly compare food temperatures to thermostat settings.

Refrigerant Leaks

Excess refrigerant leakage not only costs money, but it may also violate environmental regulations and pose a safety risk. Repair substantial leaks (20% in one calendar year) within 30 days of when refrigerant was last added to the equipment.

Secure the Savings

Refrigeration commissioning is a great way to uncover design problems or operating issues affecting performance. The ASHRAE Refrigeration Commissioning Guide can help. Download the guide free of charge at https://refcx.ashrae.org/.