Sustainable business practices are rapidly gaining priority as rising energy costs, evolving regulations and increasing consumer demand for environmentally friendly solutions drive change. In the refrigeration industry, the choice of refrigerant directly affects both energy costs and regulatory compliance. This blog will explore the advantages and disadvantages of low-globlal warming potential (GWP) refrigerants; Natural and Hydrofluoroolefin (HFO).

In 2002, a severe drought agonized 33% of the contiguous United States. Crops and pastures were ruined, wells ran dry, and reservoirs were drained. In Colorado, over 3 million people lost their water security. Water restrictions were put in place. Outdoor lawn watering, accounting for half of annual residential water use, could only be done once a week and was scheduled by address numbers. Swimming pools could not be filled during one of the warmest summers on record. After the drought broke, planning for the next one became a priority. An expansion project began on Colorado’s Gross Reservoir Dam, located in Boulder County, to prevent water scarcity in the future.

The dam is going to be raised by 131 feet (totaling 471 feet) to increase the reservoir’s capacity by 25 billion gallons of water. After the dam’s expansion, it will be 3 times its current size and the tallest concrete dam in Colorado. Although this project has many challenges, one in particular caught the attention of Zero Zone: the heat concrete produces as it cures.

The Hybrid™ merchandiser provides the flexibility of a self-contained display case while maintaining the durability and sales capability of those in large supermarkets. Each Hybrid™ merchandiser inherits the traits of its remote counterpart and has all the necessary refrigeration components mounted on top of the display case. These cases require minimal effort to install. After connecting the remote condensing unit to the display case, they are ready to be energized for operation. With medium- and low-temperature options, you can display beverage, bakery, dairy, deli, floral, frozen food, meat, produce, or seafood products in an environment that will keep them fresh.

Zero Zone Hybrid™ merchandisers provide benefits for a store of any size. They allow small format stores to effectively and efficiently use their floorspace for merchandising products rather than taking up valuable real estate for the refrigeration system. Large format retailers can add a Hybrid™ merchandiser to the sales floor without increasing the installed system’s load or the need for additional refrigeration piping.

A walk-in cooler turns into an oasis during the summer months. While this may bring you relief, it adds stress to your commercial or industrial refrigeration system. The efficiency of any refrigeration system drops as the ambient temperature increases. Pressure within the system also increases, putting strain on the entire system. For areas with warmer climates, this happens for a longer period of time during the year. There are many ways to mitigate stress and heat in your system, but which one works best for your application?

The Highlight Merchandiser^® is a durable display case with classic charm. This workhorse offers a generous packout and a spectacular, full view of your product. Whether it’s protecting your frozen food, ice cream, beverage, dairy, deli, meat, ice, or produce, the Highlight Merchandiser^® is up to the task.

Zero Zone reliability has built a trust with customers across North America. This trust grew from our small town in Wisconsin by selling to local retailers, such as Webster’s Marketplace. When Webster’s Marketplace expands, they choose Zero Zone for their display cases. DuWayne Wichman, one of the store directors, has said in an interview, “I can’t say enough good things about [Zero Zone display cases].” Inside Webster’s Marketplace, you’ll find Zero Zone display cases in operation from 1984, 2005, 2015, 2017, and 2024.

The Reveal Merchandiser® matches the diversity of your product with a variety of features. It has options for beverages, dairy, deli, meat, and produce. The multitude of lighting, shelf, and accessory options put you in control of creative merchandising. Read on to learn more about how you can “deck” out a Zero Zone Reveal Merchandiser®.

The Lineup

Before we can accessorize a display case, we have to know what we are working with. Zero Zone has four models for the Reveal Merchandiser® display case.

What is the difference between retail and industrial refrigeration? For starters, they are at different stages in the Cold Chain, a temperature-controlled supply chain of perishable goods. This supply chain starts with storage, processing, or both. Then it moves to transportation, then arrives at the final step, distribution. Retail refrigeration exists within the distribution step; think of places that need refrigeration and have a checkout counter. Industrial refrigeration exists before refrigeration at the retail level. Before we venture into the specifics of industrial refrigeration, let’s look at some common applications where Zero Zone systems have been used.

The Zero Zone Crystal Merchandiser® is more than a display case to keep your products cold, it is used to show off your product’s best features. The Crystal Merchandiser® is best used for floral displays, produce, dairy, deli, wine, beverages, ice cream, and frozen foods. The versatility of the Crystal Merchandiser® does not end with what can be displayed, but how its contents can be displayed.

What is a Small Format Store?

Small-format stores are usually less than 25,000 ft² and require less than 30 tons of refrigeration capacity. Typically, these stores are convenience stores, small grocery stores, and pharmacies. Due to their size, Small-format stores do not have the space or lease agreement to install the large rack units that are favored by Large-format retailers. Another complication is how the small-format store needs to be organized for the display cases to fit.

Why CO₂?

• Carbon dioxide (CO₂) as refrigerant:
  • Significantly reduces the environmental impact and plays a crucial role in combating climate change
  • Is the gold standard for ozone depletion potential (ODP) at 0
  • Has a global warming potential (GWP) at 1.

Many countries including the US are phasing out the use of high-GWP synthetic refrigerants, and stricter environmental regulations are being enforced. Embracing CO2 makes this a future-proof solution as it ensures compliance with these evolving regulations, avoiding penalties and legal complications.

CO2 is nonflammable and nontoxic, and it is a low-cost refrigerant. The recent advent of high-pressure, iron-impregnated copper has allowed the traditionally stainless-steel piping to transition to familiar brazed copper piping, further improving value and simplifying repairs.

Is CO₂ Right for your Small Format Store?

CO₂ is also a low-cost refrigerant. Most synthetic refrigerants can cost upwards of $20 per lb, whereas the current price of CO₂ is around $3 per lb. CO₂ systems require smaller copper pipes than other refrigeration systems, which decreases the installation costs. CO₂ systems also have excellent energy efficiency, minimizing the operation cost. It’s high density and low viscosity increase coil efficiency, allow for smaller line sizes, and take advantage of smaller compressors.

Although everyone with a CO₂ system can enjoy its benefits, small-format stores can go a step further. Since small-format refrigeration systems require less refrigerant, they do not require heat removal through air conditioning. This means the heat reclaim can be used for space heating, dehumidification, commercial kitchens, and restrooms.

Zero Zone knows that one size does not fit all. Our Genesys™ Natural Refrigeration Systems can be tailored for small format stores with the following products.

 

 

 

 

Here are some case studies of using Zero Zone’s CO2 Genesys™ Natural Refrigeration Systems in small format stores:

• Small grocery store in Stapleton, CO
  • Zero Zone completed this project using an indoor parallel system that can operate on a mezzanine in a mechanical room in a  5B climate zone. It has a remote adiabatic gas cooler, negating the need for air conditioning. The design pressure is 120 bar on the high side and 45 bar on the low side.

• Small format store in Islandia, NY
  • This store is located in a  4A climate zone and home to one of Zero Zone’s outdoor parallel roof-mounted rack systems. This system has a remote air-cooled gas cooler and a design pressure of 120 bar high side and 90 bar low side.

• Convenience Store in Dayton, MN
  • Zero Zone also has an outdoor parallel system mounted on the roof in a  6A climate zone. This system measures 120 bar on its high side and 45 bar on its low side. This location also uses the heat reclaim for heating the backroom air coil and water.

A common myth surrounding CO₂ as a refrigerant is that it can only be used in certain climates. This is true only for certain types of CO₂ systems. Transcritical CO₂ systems can only be used in cooler climate zones. Subcritical CO₂ systems can be used in any climate zone. At Zero Zone, we have a solution for natural refrigerants in any climate.

Are You Ready for Zero Zone’s Genesys™ CO­₂ System?

To start a project or learn more about how Zero Zone can help, contact one of our sales representatives.