When making your New Year’s resolution, you possibly resolved to save more and spend less. How can retailers like you continue to save money with your commercial refrigeration equipment?

Every grocery store requires thousands of kilowatt-hours (kWh) of electricity per year to operate. This electricity covers refrigeration, ventilation, lighting, cooking, heating and cooling, and office. But the overwhelming majority of electricity goes to commercial refrigeration equipment that runs whether the store is open or not. This makes refrigeration an obvious target for energy and cost savings.

Through some simple investigation and adjustments, you could benefit from energy savings. Check out some steps our product managers and engineering team recommend to get the most out of your commercial refrigeration equipment.

Evaluate Energy Consumption

First, collect data about the energy that your commercial refrigeration equipment uses by referring to the component specification sheets. You should verify that the equipment is operating at the specified temperatures. If not, the controls could be set too cold, which wastes energy, or there could be a performance issue such as an iced coil or low refrigerant charge. If you notice equipment is not operating correctly, contact your refrigeration contractor.

You can also contact your utility company. Ask if they can perform an energy audit to compare your energy usage to similar businesses that use commercial refrigeration equipment. They may even suggest ways to improve the efficiency of your equipment.

In addition to checking your commercial refrigeration equipment, look at your HVAC system settings. Refrigerated display cases are designed to operate in ambient temperatures of 75°F and 55% relative humidity (defined by ASHRAE). Ensuring that your HVAC equipment maintains good store conditions will reduce commercial refrigeration equipment energy consumption, and it is more cost effective to have the HVAC equipment cooling the store instead of having the display cases dehumidifying it.

Install Energy-Saving Features

There are many features available that are designed to reduce energy usage and provide cost savings down the road for your commercial refrigeration equipment.

Motion sensors, which turn display case lights off when no shoppers are around, have a relatively quick payoff. Anti-fog coating is a clear film on doors that prevents fog buildup and helps shoppers see products. Over time, this leads to energy savings because the case does not get opened unnecessarily, which means less energy is consumed to cool the case. Most display cases come with standard anti-sweat heaters that limit door sweating in humid conditions, but they can run too aggressively in cooler, drier stores. Consider ordering your next display case with an anti-sweat controller, which cycles the heaters off when there is less humidity in the air, thereby saving energy. Also contact your refrigeration manufacturer. They may be able to offer other features to reduce energy consumption for your commercial refrigeration equipment.

Schedule Routine Maintenance

It pays to be proactive and schedule regular maintenance for your commercial refrigeration equipment. Instead of waiting for an issue to happen, you should schedule regular visits from your refrigeration contractor to keep the equipment running efficiently and catch component failures early.

General cleaning and maintenance is important for efficient case operation. You should clean doors and windowed ends so people can see product. Regularly clean lint and dust accumulation off of condenser coils and discharge air grills. On a monthly basis, ensure gaskets are not torn, doors are at ideal tension, and all fans are operating.

To check gaskets, simply place a dollar bill in the door track. If the dollar slides out with little to no resistance, it’s time to have the seals replaced or adjusted. To check ideal door tension, open the door and observe how well it closes. A properly tensioned door will close itself gently and not swing open. If the door does not close or swings open, the case will not operate optimally. There are two ways to check fan operation. One way is to put your hand near the discharge air grills. If all fans are working, the airflow will be the same from door to door. If less air is coming out, a fan may not be working. However, the most effective way to check fan operation is to unload product, take out the cover, and visually confirm that the fan is working. Do not put your hand into the fan, even if it appears to not be operating.

With so many steps available for reducing your refrigeration energy consumption, it is wise to develop a plan. Even if the budget does not allow for a full equipment overhaul, you may be able to update your cases department-by-department. That allows you to stay within budget, and your New Year’s resolution will be off to a good start!

Maximize your savings this year! Contact us to learn more about energy-efficient commercial refrigeration equipment solutions.

Maximizing Product Appeal: Strategic Use of Retail Display Cases in Modern Supermarkets

In the competitive landscape of modern retail, particularly within the grocery sector, the strategic deployment of retail display cases is paramount to captivating customers and driving sales. Retailers are constantly seeking innovative ways to showcase their products, ensuring optimal freshness and visual appeal. To gain valuable insights, we turned to Mike Floersch, owner of Ray’s Apple Market in Seneca, Kansas, and Marc Robért III, general manager of Robért Fresh Market in New Orleans, Louisiana, to discuss their merchandising strategies using open multi-deck and reach-in display cases.

The Allure of Open Multi-Deck Retail Display Cases

Both Ray’s Apple Market and Robért Fresh Market have embraced the Reveal Merchandiser® open multi-deck for their produce displays. This choice underscores the inherent appeal of fresh fruits and vegetables when presented in an open format. “I did not want to put produce behind doors,” Floersch explained, drawing upon his extensive experience in the grocery business. “I’ve been in the business 50-some years, and I felt like it presented itself well.” The open design of these retail display cases allows the vibrant colors and natural textures of the produce to take center stage, creating an inviting and visually stimulating shopping experience.

Robért Fresh Market has further elevated this approach by creating a dramatic “showstopper” display, featuring a 54-foot run of Reveal Merchandiser® cases strategically positioned at the store’s entrance. This impactful presentation immediately captures the attention of shoppers, emphasizing the store’s commitment to freshness and quality. The versatility of these open retail display cases extends beyond produce, as Robért Fresh Market also utilizes them for showcasing fresh meats. “That bright red meat color really pops, and it’s all about ‘eye appeal is buy appeal,'” Robért noted. He also emphasized the enhanced accessibility of products in open cases, allowing customers to easily browse and select their desired items.

The Practicality and Efficiency of Reach-In Retail Display Cases

While open multi-decks excel in visual merchandising, reach-in display cases, such as the Crystal Merchandiser® and Highlight Merchandiser®, offer distinct advantages for other refrigerated products. Both retailers have opted for these cases to display dairy, deli, and frozen foods. The key feature of Zero Zone’s reach-in merchandisers is the CoolView® doors, which boast a sleek, narrow design that maximizes display area and provides excellent product visibility. These retail display cases offer a clean and organized aesthetic, contributing to a pleasant shopping environment.

For stores located in humid regions like New Orleans, the performance of reach-in cases is critical. The CoolView® doors are equipped with heaters in the doors, door rails, mullions, and sills, effectively preventing condensation. Robért has been particularly pleased with the performance of these retail display cases in his high-humidity environment. “With our high humidity environment, I have found that [Zero Zone] has been a perfect match and that we’ve had zero issues with sweating and humidity issues coming onto our product,” he stated.

Floersch, initially hesitant about using reach-in cases, has also experienced positive feedback from his customers. “A lot of stores you go into, it’s cold, and it’s because of all the open cases,” he observed. His shoppers appreciate the warmer environment created by the reach-in cases, highlighting the importance of customer comfort.

A Comprehensive Solution for Every Retailer

Whether a retailer prefers open multi-decks, reach-in display cases, or a combination of both, Zero Zone offers a comprehensive range of solutions to meet their specific needs. Robért emphasized how the combination of Zero Zone’s retail display cases has “brought the décor and the feel of the whole store together.” Floersch highlighted the significant cost savings achieved through a 25% reduction in kilowatt usage. Ultimately, both retailers agree that selecting Zero Zone as their refrigeration partner was the optimal decision, providing a complete and effective solution for their merchandising needs. The right selection of retail display cases can truly transform a retail space.

Learn more about our retail display case solutions!

The pursuit of freshness unites two distinct family-owned supermarket chains, Ray’s Apple Market in Seneca, Kansas and Robért Fresh Market in New Orleans, Louisiana, despite their geographical separation. Both understand that the key to thriving in today’s competitive grocery landscape lies in delivering superior perishables. Central to their strategies is the strategic implementation of the retail display case, a crucial element in maintaining product quality and visual appeal.

Robért Fresh Market prioritizes produce as its “showstopper,” utilizing a 54-foot run of open Reveal Merchandiser^® cases. This choice highlights the importance of visual merchandising, where the vibrant colors and fresh appearance of produce drive impulse purchases. The open retail display case allows shoppers to fully engage with the product, emphasizing freshness and quality. This approach reflects the understanding that in produce, “eye appeal is buy appeal.”

Similarly, Robért Fresh Market extends the use of open retail display cases to their meat department, where the rich colors of beef, poultry, and pork are showcased. Ray’s Apple Market, however, opts for reach-in cases for their meat, emphasizing product longevity and reduced shrink. These reach-in retail display cases provide a clean and organized appearance, enhancing the perception of freshness among shoppers. Owner Mike Floersch notes a significant reduction in shrink, attributing it to the superior preservation capabilities of these cases.

The choice of retail display case directly impacts product lifespan and consumer perception. While open cases excel in visual merchandising and impulse buying, reach-in cases offer superior temperature control and reduce product waste. Both Ray’s Apple Market and Robért Fresh Market have tailored their refrigeration strategies to align with their specific needs, demonstrating the versatility and importance of selecting the right display solution for maintaining the highest standards of freshness.

Learn more about their refrigeration strategies using Zero Zone!

The United States Environmental Protection Agency (EPA) regulates which refrigerants may be used and how refrigerants must be handled. It is important to note that individual states may write their own refrigeration regulations above and beyond the EPA regulations.

Since 2015, EPA has proposed several rules, but some of those rules have been vacated in court. We understand that it may be confusing which rules still apply. Please read below to understand which regulations will come into effect in January 2019.

SNAP Program, Prohibited Refrigerants, and California

What is the SNAP Program?

EPA regulates which refrigerants may be used for new or retrofit refrigeration through the Significant New Alternatives Policy (SNAP) program.

Which refrigerants were affected by recent EPA rules?

EPA released Rule 20 and Rule 21 through its SNAP program, which delisted refrigerants with high global warming potential (GWP). This prohibited common refrigerants such as R-134A, R-404A, and R-507A. However, EPA was challenged in court and lost on Rule 20, which means it has been vacated and will not go into effect. It is possible that Rule 21 will also be vacated, but the courts are still evaluating it. Use the links below for more information:

• Zero Zone Guide to 2017 EPA Retail Refrigeration Regulations: Download
• Rule 20 Factsheet: https://www.epa.gov/sites/production/files/2015-08/documents/snap_regulatory_factsheet_july20_2015.pdf
• Rule 20 Vacated: https://www.gpo.gov/fdsys/pkg/FR-2018-04-27/pdf/2018-08310.pdf
• Rule 20 Allows R-404A: /refrigerant-regulations-update/
• Rule 21 Factsheet: https://www.epa.gov/sites/production/files/2016-12/documents/snap_action_scr2_factsheet.pdf

Can high GWP refrigerants be used?

Yes, depending on state. Rule 20 was vacated on a national level, but individual states may pass their own refrigeration regulations. In 2018, California passed a regulation that adopts Rule 20 (called Rule 1 in California). This rule prohibits high GWP refrigerants in California after January 1, 2019. More information is available on California legislature’s website: http://leginfo.legislature.ca.gov/faces/billNavClient.xhtml?bill_id=201720180SB1013

High GWP refrigerants can continue to be used in all other states, but that may change too. California is a member of the United States Climate Alliance (USCA), and the other states will likely adopt similar regulations. This includes Colorado, Connecticut, Delaware, Hawaii, Maryland, Massachusetts, Minnesota, New Jersey, North Carolina, Oregon, Rhode Island, Vermont, Virginia, and Washington.

In summary, R-134A, R-404A, and R-507A may be used in all states except California, which prohibits those refrigerants. However, other states in the USCA are likely to prohibit those refrigerants in the coming years.

Section 608, Record Keeping, and Leakage Rates

What is Section 608?

EPA regulates how refrigerants are handled through Section 608 of the Clean Air Act. Section 608 affects many sectors in the refrigeration industry:

• Technician Certification
• Refrigerant Recovery and/or Recycling Equipment
• Refrigerant Leaks
• Refrigerant Sales
• Record Keeping
• Safe Disposal
• Reclamation
• Service Practices

For more detail on how Section 608 applies, visit https://www.epa.gov/sites/production/files/2018-09/documents/section_608_of_the_clean_air_act.pdf

What are the new Section 608 regulations?

EPA issued new regulations that 1) require owner/operators to keep additional records for their refrigeration systems, and 2) change the allowable leakage rates for refrigeration systems. These rules affect ozone depleting refrigerants and will take effect on January 1, 2019.

The new rule included refrigerants with high GWP such as R-134A, R-404A, and R-507A. However, EPA proposed to omit refrigerants with high GWP from the rule. This has not been finalized, so more information will be provided as it becomes available. Use the links below for further reading.

• Summary of the Rule: https://www.epa.gov/sites/production/files/2016-09/documents/608_fact_sheet_supermarkets_property_managers_0.pdf
• Official Revision Announcement: https://www.epa.gov/section608/revised-section-608-refrigerant-management-regulations

What records does an owner/operator need to keep?

• Full System Charge
• Service Work Invoices
• Installation and Calibration of Automated Leak Detection System (if applicable)
• Leak History
• Reports for Leakage Rate Greater than 125% of Full-Charge in a Year
• Retrofit or Retirement Plans
• Requests to the EPA
• System Mothballing Reports
• Seasonal Variance Records

What are the allowable system leakage rates?

EPA reduced the allowable leakage rates. Annual leakage rates are calculated as a percentage of the full system charge. Details for calculating leakage rates can be found at https://www.epa.gov/sites/production/files/2016-09/documents/608_fact_sheet_supermarkets_property_managers_0.pdf.

What must be done when a leak is found?

If leakage rate exceeds allowable rates, the system must be repaired, retired, or replaced.

Repair: If a leak is repaired, the technician must ensure the system is leak-free before adding refrigerant. After refrigerant is added, the technician must check the repair again after the system returns to normal temperatures and pressures. Information for technicians can be found at https://www.epa.gov/sites/production/files/2016-09/documents/608_fact_sheet_technicians_0.pdf.

Retire or Replace: Owner/operators must develop a retrofit or retirement plan within 30 days if the leak cannot be repaired. The plan must be implemented within 1 year. If the leak is repaired within 180 days, the plan can be terminated and the system can be used.

What must be done after a leak?

After a leak, systems must be checked for leaks based on the schedule below. All visible, accessible parts of the systems must be inspected.

• Refrigeration systems with over 500 lb. refrigerant charge must be inspected every 3 months until the leakage rate is below the annual requirement.
• Refrigeration systems with between 50 and 500 lb. refrigerant charge must be inspected every year until the leakage rate is below the annual requirement.
• Refrigeration systems with a leak detection system do not require regular leak inspections. However, the leak detection system must be calibrated annually.

When should a leak be reported to EPA?

If the annual leakage rate of a refrigeration system exceeds 125% of the full charge within a calendar year, owner/operators must notify EPA by March 1 of the subsequent year and describe their efforts to identify and repair leaks.

Zero Zone’s commitment to advancing the field of refrigeration is exemplified by the significant contributions of three of its engineers to the 2018 ASHRAE Handbook. Mike Chieffo, Bruce Hierlmeier PE, and Carl Roberts received special recognition for their extensive work, solidifying Zero Zone’s position as a leader in the industry. Notably, Hierlmeier and Roberts have dedicated over two decades to this endeavor, while Chieffo contributed for the first time, making Zero Zone the most represented individual refrigeration manufacturer.

Their collective efforts focused on updating and refining two crucial chapters: “Retail Food Store Refrigeration and Equipment” and “Food Service and General Commercial Refrigeration Equipment.” They diligently incorporated the latest technical information and removed outdated data, ensuring the handbook remained a relevant and accurate resource. The additions reflected the dynamic nature of the refrigeration industry, encompassing recent technological advancements, evolving regulations, and a growing emphasis on sustainability and energy efficiency.

Key topics addressed included innovative design enhancements and the introduction of new refrigerants. The engineers provided in-depth coverage of high glide refrigerants, propane, and CO2, with particular attention to transcritical CO2 systems. These advancements underscore the industry’s shift towards more environmentally friendly solutions.

Zero Zone takes immense pride in their engineers’ contributions to the 2018 ASHRAE Handbook, a publication widely used by engineers and government agencies responsible for developing regulations. Their dedication to sharing expertise and promoting best practices reinforces Zero Zone’s commitment to driving innovation and sustainability within the refrigeration sector.

Learn more about the expertise Zero Zone has in refrigeration!

In 2005, Hurricane Katrina destroyed all Robért Fresh Market locations. But 2018 marks a milestone as the New Orleans-based supermarket opened their sixth location and moves beyond the hurricane. “This particular location is a historic landmark,” General Manager Marc Robért III explained. “It was the first self-service grocery store in the city of New Orleans in 1941.” Even after being devastated by Katrina, the store still has some of the original terracotta and pine timbers.

Zero Zone provided refrigeration solutions as Robért Fresh Market rebuilt. “I worked with many vendors to get this store open, whether it was equipment vendors, décor vendors, lighting, and so on. I found that Zero Zone was an excellent vendor to work with,” Marc said.

Marc Robért chose Zero Zone to help achieve their mission of freshness. “We are Robért Fresh Market,” Marc emphasized. “We focus on fresh, locally-sourced, organic produce.” For produce and fresh meats, Marc chose the Zero Zone Reveal Merchandiser^® open case as the “impactful showstopper” at the entrance of the store. “As you walk through the front of our store and get through the vestibule, you see this case, there’s a visual line-of-sight to this case, the colors pop well, and the LED lights within the case really help bring the product to life.” He added that for vibrant products like produce and fresh meat, “eye appeal is buy appeal,” and the open display cases work perfectly for that.

For displaying other refrigerated products, he chose Zero Zone Crystal Merchandiser^® reach-in coolers and Highlight Merchandiser^® reach-in freezers. “The door cases make a very clean and neat presentation. I’ve heard concerns about putting product behind doors, but I feel that the doors create a nice, clean look to the store, and customers appreciate seeing that level of cleanliness.” Also, Marc is pleased that the Zero Zone door cases perform well in the hot, humid New Orleans climate. Marc reports that they have not had any door sweating issues.

With six locations open, Robért Fresh Market forges onward from Hurricane Katrina. They project growth for their company, and they can confidently move forward as partners with Zero Zone. “I will be using Zero Zone in the future,” he says. Zero Zone is proud to have been chosen to provide refrigerated display cases and refrigeration systems to Robért Fresh Market and wants to be your trusted partner for refrigeration solutions, too.

In the dynamic world of retail, the strategic use of space is paramount to achieving optimal merchandising and driving sales. Balancing customer flow with product visibility presents a continuous challenge, demanding retailers to maximize every available inch. This is where the intelligent implementation of a refrigerated food display case becomes an indispensable asset. However, traditional store layouts, particularly those featuring established gondola shelving, often impose limitations on merchandising flexibility, hindering the ability to create impactful displays.

Zero Zone’s Crystal Merchandiser® Ultra Narrow display case is meticulously engineered to address and overcome these spatial constraints. Specifically designed for seamless integration with gondola shelving, this innovative refrigerated food display case transforms previously underutilized end-of-aisle spaces into high-impact, grab-and-go zones. This strategic end-cap design effectively captures customer attention, driving impulse purchases and significantly boosting sales.

Furthermore, the availability of a back-to-back configuration for the Ultra Narrow model significantly enhances its space-saving capabilities. This ingenious design enables seamless integration within existing shelving lines, creating a continuous and visually appealing merchandising presentation. The remarkably slim profile of this refrigerated food display case, measuring a mere 55 inches from handle to handle, ensures minimal disruption to valuable aisle space, maintaining optimal customer flow.

Consistent customer feedback underscores the profound positive impact of this innovative solution. Store managers have reported a notable increase in customer engagement and a substantial surge in sales. The sleek design and efficient functionality of the Crystal Merchandiser® Ultra Narrow refrigerated food display case have resonated profoundly with shoppers, demonstrating its exceptional effectiveness in maximizing merchandising potential within constrained environments. Zero Zone’s unwavering dedication to customer-centric solutions is clearly evident in this product, providing retailers with the essential tools necessary to optimize their store layouts and elevate the overall customer experience, ultimately driving profitability and enhancing brand perception.

View or download the product sheet! Ultra Narrow and Back-to-Back Ultra Narrow spec sheets are also available.

Ray’s Apple Market, a testament to enduring customer service, has strategically upgraded its commercial refrigeration systems, reinforcing its commitment to quality. Founded on the principle of treating customers right, Ray Floersch established the market in 1965, driven by his dissatisfaction with previous employer practices. Over five decades later, his son Mike continues this legacy, emphasizing strong partnerships. “We have a partnership with our customers. We want our customers to trust us. That’s how I feel about Zero Zone: they’re a partner. They trust me, and I trust them,” Mike states, highlighting the mutual trust developed during the 2017 commercial refrigeration installation.

The market’s focus on perishables, stemming from the Associated Wholesale Grocers’ “Apple” merchandising approach, necessitated advanced commercial refrigeration solutions. “We feel like that’s where we need to be the best… perishables. You can buy groceries about anywhere today, but if we have the freshest meat, freshest produce, people will shop with you,” Mike explains. He opted for the open Reveal Merchandiser™ for produce, recognizing its superior presentation, and transitioned to Zero Zone reach-in cases for other products. “I was a little nervous about putting things behind doors, but I’m so glad I have,” Mike admits, praising the LED lighting and tall doors for enhancing product visibility within their new commercial refrigeration setup.

A significant benefit of the Zero Zone commercial refrigeration upgrade was the substantial reduction in energy consumption. By replacing individual compressor units with two centralized rack systems, Ray’s Apple Market dramatically lowered its monthly energy bill. “As the months went along, we could see our kilowatt [usage] lowering. I’m thinking we’re going to be looking at about a 20,000 kilowatt drop, which is about a 25% drop in energy usage,” Mike reports. “Zero Zone helped us cut our energy costs, which we can pass on to our customers.”

Furthermore, the store streamlined its refrigerant usage, moving from multiple refrigerants, including outdated R-12, to a single, more efficient R-448A. This decision was influenced by evolving EPA regulations and installation costs. “The copper tubing was smaller. When we compared the lines we took out to what we put in, it was almost like, ‘Really? Is this going to work?’ And it’s been great,” Mike says, expressing satisfaction with the new commercial refrigeration system’s performance.

Mike also praised the Zero Zone sales representative’s dedication, highlighting their presence during every installation phase. “I do not have to buy from Zero Zone, but when I get the kind of response they give me, then I’m sold,” Mike concludes, emphasizing the value of Zero Zone’s exceptional customer service and the quality of their commercial refrigeration solutions.

Learn more about our commercial refrigeration solutions!