Refrigeration systems

Please note: This article is for educational purposes only. Always consult a qualified refrigeration engineer before making any changes to your commercial refrigeration systems.

Commercial refrigeration can account for over 50% of a site’s total energy usage, making it one of the most significant opportunities for energy and cost savings in food retail, hospitality, and manufacturing. Understanding how refrigeration systems work and where efficiency gains can be made is essential for businesses looking to reduce their energy bills and carbon footprint.

Contents

1. What is Refrigeration?
2. Potential Energy Savings on Refrigeration
3. Heat Recovery
4. F-Gas Regulations

What is Refrigeration?

Refrigeration is a mechanical process by which heat is removed from one location and moved elsewhere. This factsheet focuses on vapour compression refrigeration systems, which use refrigerants to transfer heat. These systems are used primarily in commercial situations to prolong product life and reduce spoilage, and in some sites can account for well over 50% of total energy consumption.

A refrigerator operates through four main components: the evaporator, compressor, condenser, and expansion valve. Refrigerant passes through these parts in a continuous cycle, absorbing heat from the items being cooled and expelling it elsewhere.

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Potential Energy Savings on Refrigeration

Energy savings can be achieved across all major components of a refrigeration system:

• Evaporators absorb heat from refrigerated items and require regular maintenance to prevent ice buildup, which reduces heat transfer efficiency and increases energy consumption.
• Compressors raise refrigerant gas pressure and temperature. Efficiency gains can be achieved by lowering condensing temperatures and utilising variable speed drives (VSDs) to match compressor output to actual demand.
• Condensers cool refrigerant vapour back to liquid and require regular cleaning and maintenance. Proper placement to avoid hot or restricted airflow environments and energy-efficient upgrades can significantly improve performance.
• Refrigerated display cabinets and cold rooms offer further savings through operational management strategies, hardware upgrades such as door seals and night blinds, and compliance with current efficiency standards.

These measures, implemented with expert assistance, promote sustainability, reduce energy consumption, and cut costs in commercial refrigeration operations. Refrigeration improvements also contribute directly to Carbon Reduction Plan targets by reducing Scope 2 electricity consumption.

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Heat Recovery

Rejected heat in a refrigeration system is usually expelled as waste. For sites that also have a heating requirement, this resource can sometimes be recovered and utilised. Both high and low grade heat can be recovered to preheat water or support space heating, reducing the energy demand from dedicated heating systems such as heat pumps or gas boilers.

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F-Gas Regulations

F-Gas regulations govern the use of hydrofluorocarbon (HFC) refrigerants due to their high global warming potential (GWP). Key compliance requirements include:

• Businesses must keep records for equipment containing F-gases equivalent to 5 tonnes or more of CO₂, documenting installation, maintenance, and leak checks for a minimum of 5 years.
• Failure to comply with required leak checks and fixes is illegal.
• Since 2020, only recovered gases can be used to top up existing refrigeration systems — virgin HFC refrigerants can no longer be used for servicing.
• Phasing out of certain high-GWP refrigerants is ongoing, requiring businesses to plan ahead for compliant replacements.

Staying compliant with F-Gas regulations not only avoids legal penalties but also futureproofs your refrigeration systems and reduces your contribution to greenhouse gas emissions. For broader emissions reporting context, refrigerant leakage falls under Scope 1 emissions in your carbon footprint.

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