Refrigeration & Food Service
For business that must keep perishable goods at the proper temperature, refrigeration equipment can account for about 60% of their energy usage. Maintaining this equipment for efficient operation is vital to prevent product spoilage and keep related energy costs under control.
Although this equipment is cost-intensive to upgrade, there are less-expensive steps that can help control energy costs. Some of the most cost effective measures ensure that the cooling energy stays inside the unit. And if the equipment is nearing the end of its useful life, there are highly energy-efficient options.
Also, be sure not to overlook the no-cost savings opportunities such as:
- Keep all coils clean
The condenser coils are where the heat is rejected or removed from the refrigerant (cooling fluid). They are external to the conditioned space and usually have a fan circulating air through or over them. The combination of a fan and dusty surroundings leads to dirty coils that can become clogged with debris preventing efficient heat removal. Dirty coils can increase system energy usage by about 20%.
The evaporator coils are where the heat is removed from the air inside the refrigerated space. They are located inside the conditioned space. Ice can build up on them and is usually cleaned away during the defrost cycle. Be sure your automatic defrost cycle is functioning properly or manually defrost the unit when you notice ice buildup.
- Defrost regularly
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 Door Auto-Closer
Walk-in coolers and freezers are designed to be accessed regularly, but leaving the main door open wastes a great amount of cooling energy and money. Auto-closers ensure that the door is fully closed after each access and remove the need to check if door is completely shut.
The reach-in doors or walk-ins coolers and freezers are also accessed regularly-auto-closers can make sure they are closed after each access. A properly installed walk-in door closer should firmly close a main walk-in door that is within one inch of full closure. For a reach-in door, the closer should also firmly close the door.
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 Strip Curtains
For walk-in units that are accessed constantly, strip curtains keep the cool in and the heat out when unit is being used and doors are open. Strip curtains also improve sanitary conditions by preventing dust, pollen, smoke, odors, and flying insects from entering refrigerated areas.
Strip curtains used in busy kitchens can reduce compressor runtime significantly and that saves you money! Remember, strip curtains have to cover the entire door opening - that old curtain with the center strips chopped out is wasting your money, so replace it and save!
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 Door Gasket
Even though your cooling unit doors are shut, worn out gaskets can allow cooling energy to escape and increase your energy costs. Door gaskets keep air leakage to a minimum and are easy to install and maintain. The seals around the perimeter of your doors should be checked regularly and replaced when they are deformed or torn.
Replacement gaskets should meet the manufacturer's installation specifications regarding dimensions, materials, attachment method, style, compression, and magnetism.
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 Night Cover for Display Case
For cases that must be open for product access during operational hours, night covers are a quick and easy way to save cooling energy and cost during non-operational hours, especially at night when there are no customers. They are easy to install and reduce the amount of refrigeration necessary. They can fit vertical and horizontal types of cases. |
Anti-Sweat Heater Control
Anti-sweat heaters warm glass doors during periods of high humidity to reduce condensation. However, they use energy during this heating process. Anti-sweat heater controls turn off the heaters when the humidity is low and only power the heaters when conditions would create condensation.
Low/No Anti-Sweat Heat Display Case Doors
Anti-sweat heaters warm glass doors during periods of high humidity to reduce condensation. However, they use energy during this heating process. Doors with low or no anti-sweat heat are designed to prevent condensation with little or no heating energy.
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 Evaporator Fan Controller
Reduces airflow when compressor is not running. Fan motor power is reduced by at least 75% when controller is operating.
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 New Display Case with Doors
New display cases are more efficient than older models. Although this equipment is cost-intensive to upgrade, if the equipment is nearing the end of its useful life, there are highly energy-efficient options. Features to look for are efficient lights and motors.
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Suction Line Insulation
For suction lines that are accessible, this is a very cost effective upgrade. The suction line delivers the cold refrigerant to the refrigerated unit to keep it cool. Insulating this line prevents the fluid from heating prematurely and maximizes the efficiency of your system and reduces the compressor's energy usage. The insulation is for use on bare refrigeration suction lines.
The hot high-pressure lines returning to the compressor should not be insulated. In this case it is desirable for the line to release heat. However, if this line is in your conditioned retail space, the released heat will become a load for your air conditioner.
The insulation material should be flexible closed-cell nitrite rubber or equivalent. Medium temperature lines should be insulated with 3/4-inch insulation and low temperature lines should have 1-inch insulation.
Energy Efficient Condenser
Newer models are dramatically more efficient. Retrofit air-cooled systems should operate at 8°F Temperature Difference (TD) for low temperature and 13°F TD for medium temperature systems with EER of 105 Btu/hr/Watt (for the condenser only). Retrofit evaporatively cooled systems should operate at 18°F TD above ambient wet-bulb temperature with EER of 240 Btu/hr/Watt (for the condenser only). Use these new condensers with Variable Speed Drive (VSD) and variable set point floating head pressure controls for greater energy savings.
Evaporative Condenser
This type of condenser operates on the same principle as a "swamp cooler." It works very well in a dry, hot climate such as San Joaquin County. Replacement of an existing air-cooled condenser with an evaporative condenser can take place for both conventional multiplex and single compressor systems. New evaporative condenser should be sized at 25°F TD (Temperature Difference) above ambient wet bulb temperature.
High Efficiency Compressor (Multiplex System)
This parallel system can replace multiple single compressors, thereby reducing overall cost to keep perishable items cold. In a multiplex system, multiple compressors serve a specific suction group, and each suction group serves one or more line-ups having similar temperatures. High efficiency features of this system include floating head pressure by means of a variable speed fan control, and mechanical sub-cooling. Combine a high efficiency multiplex compressor system with an energy efficient condenser for greater energy savings.
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Vending Machine Controller
This is an energy control device for refrigerated vending machines that contain only non-perishable food items such as bottled and canned beverages. By cycling the compressor off when no one is nearby, you can reduce your costs to run your beverage machines by 30%. These units are simple to install, requiring about five minutes and no special tools. No matter how often people walk past the machine, they will still cycle on every two hours, thereby keeping products cool for your customers. Since the compressor runs less often, the controller also extends the life of the cooler.
Feature to look for include a passive infrared occupancy sensor to turn off fluorescent lights and compressor when surrounding area is unoccupied for 15 minutes or longer. Control logic should periodically power up machine at two-hour intervals to maintain product temperature and provide compressor protection. Also look for refurbished vending machines that include this option.
Food Service
Food preparation typically accounts for 35% of the energy consumption in the food service industry. When older equipment begins to fail, there is a great opportunity to replace it with higher efficiency equipment that will cut your utility costs.
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 Connectionless Steamers
Steamers connected to a water supply use a one-way process where cool or cold water is continually heated to create the steam used for cooking; this one-way process wastes much of the heat energy added to make the steam. New connectionless models use a cycle where the steam is created from the hot condensate in the unit so they do not have to bring the water to a boil from a cold temperature. Thus, they are more energy efficient.
Look for units with a full load efficiency of at least 50%. Premium units have full load efficiencies of 70% or greater.
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 Hot Food Holding Cabinet
New insulated hot food holding cabinets are more energy efficient than older non-insulated units. The cabinet insulation cuts heat loss and saves energy costs just as the insulation in your home does. An additional benefit is better temperature regulation to keep food fresher.
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