Cold Storage | Industrial Refrigeration System

Many of the client’s facilities were aging and required substantial electrical upgrades to support traditional electric defrost systems. The estimated cost of these upgrades ranged from $1.5-$1.8 million per site.
Across the client’s 125 planned sites, the total cost would exceed $200 million, posing a significant financial hurdle.

Solution

The client implemented hot gas defrost systems in collaboration with Zero Zone for their industrial refrigeration system. Hot gas defrost eliminates the need for electric defrost systems, reducing the electrical load and avoiding costly infrastructure upgrades such as new transformers, conduits, and municipal approvals.

Result

• Per Site Savings: $1.5-$1.8 million
• Cumulative Savings Across 125 Sites: $187.5-$225 million in avoided upgrade costs
• Energy Efficiency: Hot gas defrost systems also delivered a 35% reduction in electricity usage, with a six-year return on investment

Startup delays during system commissioning significantly impacted operations. At large hubs, delays in refrigeration readiness were costing the client $156,000–$250,000 in sales per day, while even smaller sites faced daily losses of $130,000–$140,000. Additionally, inconsistent startup processes created inefficiencies that required frequent interventions.

Solution

The client streamlined its commissioning process by collaborating closely with Zero Zone to:

• Improve communication between refrigeration contractors and system manufacturers.
• Ensure on-site support during key startup phases.
• Develop robust commissioning protocols, including early identification of potential blockers.

Result

• Minimized Delays: Commissioning processes became more efficient, reducing costly delays.
• Daily Savings: Up to $250,000 per day in lost sales avoided at large hubs.
• Improved Efficiency: A consistent two-to-three-week commissioning timeline with a 14-day burn-in period ensured systems were operational within optimal timelines.

The client sought to align its operations with sustainability goals, including achieving carbon neutrality by 2040. However, the choice of refrigerants posed challenges:

• Ammonia: While cost-effective for large systems, ammonia systems require expensive compliance with Process Safety Management (PSM) protocols, increased zoning restrictions, and 24/7 supervision by RETA-certified technicians (costing $100K–$125K per technician annually).
• Propane: Systems hold tons of pressurized propane which pose challenges in densely populated areas and require on-site support during key startup phases.

Solution

This client standardized on CO2 refrigerant systems due to their safety, regulatory advantages, and alignment with sustainability goals:

• CO2 is non-flammable and non-toxic, eliminating fire hazards and zoning restrictions.
• Industrial refrigeration systems are designed for easy maintenance, avoiding the need for highly specialized technicians.

Result

• Labor Savings: Eliminated the need for 24/7 RETA-certified ammonia technicians, reducing labor costs by $625K–$875K annually per large hub.
• Regulatory Compliance: Avoided zoning restrictions and PSM compliance costs of up to $350K annually per site.
• Sustainability Leadership: CO2 systems support the client’s carbon-neutral pledge by reducing greenhouse gas emissions and eliminating reliance on HFC or flammable refrigerants.

This client needed refrigeration systems that could withstand its demanding, high-volume operations. Previous systems had faced design and quality issues, leading to costly failures such as heater replacements and compressor breakdowns.

Solution

This client partnered with Zero Zone to design industrial refrigeration cases with:

• 90-bar internal robustness for durability under high pressure.
• Simplified piping layouts to minimize maintenance needs.
• Enhanced quality control during manufacturing to prevent failures.

Result

• System Longevity: CO2 systems are designed to last 12–15 years, with capital improvements at the mid-life point to optimize performance.
• Reduced Maintenance Costs: Robust designs minimized failures, avoiding costly repairs such as the $150,000 heater replacement at a previous site.
• Operational Resilience: Systems maintained a ±2°F variance, critical for food safety and product longevity. The client’s carbon-neutral pledge by reducing greenhouse gas emissions and eliminating reliance on Freon or flammable refrigerants.