In processing equipment services, processors should focus on five stages to get the most out of a contemporary industrial refrigeration system: • Lowering the costs of installation and maintenance • Improving productivity • Assuring the food safety • Following FSMA and HACCP requirements • Switching to more environmentally friendly refrigerants Combining techniques can bring a number of advantages. This post will look at five techniques to improve the efficiency of industrial refrigeration systems.

1. How do I optimize Industrial refrigeration system?
In processing equipment services, processors should focus on five stages to get the
most out of a contemporary industrial refrigeration system:
 Lowering the costs of installation and maintenance
 Improving productivity
 Assuring the food safety
 Following FSMA and HACCP requirements
 Switching to more environmentally friendly refrigerants
Combining techniques can bring a number of advantages. This post will look at five
techniques to improve the efficiency of industrial refrigeration systems.
1. Lowering Costs of Installation and Maintenance
By utilizing communication networks, distributed controls can minimize the number of
hardwired device runs to the central PLC system, lowering installation costs. They can
also provide more versatility and dependability.
When you give a piece of equipment intelligence, it may function as a stand-alone gadget
if the rest of the system goes down. Assume a processor wish to add a few evaporator
systems to a facility with a centralized PLC system. Instead of increasing the IO of the
centralized PLC system and adding modules, dispersed controls may be attached to the
additional evaporators and communicated with the main PLC system.

2. Distributed controls can also save time and money in new installations by reducing the
length of wire lines between IO points. Because there are fewer runs, there are fewer
copper wires, lowering the cost.
Installing new technology into older or legacy systems is another approach to save
money. Installation costs can be reduced by reusing existing cables and, where possible,
existing IO.
To install sophisticated control systems, the majority of industrial supervisory control
system vendors require new technologies. Fortunately, some companies have developed
a software library for linking to older controllers, compressors, condensers, vessels, and
the latest technology evaporators. This reduces the number of controllers that need to
be replaced in the future.
While older controllers may need to be changed if they are hazardous or in bad shape, a
processor may save money on the cost of a new controller, labor to repair it, and field
wiring by not replacing them.

3. Equipment run times are recorded and synchronized with the manufacturer's suggested
maintenance plan in predictive maintenance. Facilities can evaluate the data points
collected from various devices in the facility and detect subtle variations in behavior that
might signal equipment concerns. Taking care of these issues reduces machine
downtime, which in turn reduces production downtime.
2. Improving Productivity
Intelligent condenser control, intelligent compressor control, and load management are
three of the most effective techniques to boost efficiency.
The sliding valve in the screw compressor exposes part of the rotor within, reducing the
machine's capacity correspondingly. If the slide valve is 90% full, for example, 10% of the
capacity can be recycled back into the suction chamber. Because the input power
remains constant, the machine becomes less efficient as its capacity is lowered. How can
this be resolved? Compressor control that is intelligent or autonomous compressor
sequencing can enhance efficiency.
Many machine rooms run their machines on their own setpoints rather than in a
coordinated manner. If the machines are operated in a coordinated manner, they may be
run more efficiently by permitting only the amount of compressor capacity required to
sustain cooler or freezer production.
Floating suction is a gadget that may also be utilized. Pressure and temperature are
closely linked in all refrigeration systems. This feature may be used by an operator to
better meet the facility's load needs by floating the system suction pressure higher.
Reduced compressor operation is the payoff for this investment.
How much can a processor expect to save if these guidelines are followed? Let's start
with the definition of a tonne of refrigeration: The electricity required to melt or freeze
2,000 kg of ice each day is equal to one tonne of refrigeration. Furthermore, 1 tonne of
refrigeration equals 12,000 BTUs or 3.5 KW.
Assume that the cost of 1 kW is $0.12 for the sake of argument. The cost savings for a
50-ton decrease per day is $506.40 per day or $184,836 per year.
Intelligent condenser control is the second key method for enhancing efficiency.
Automatic condenser staging and floating pressure with wet-bulb management are the
two primary types available. In an industrial refrigeration system, condensers can account
for up to 20% of the total energy usage. They have a direct impact on the overall efficiency
of the business. This can be reduced by controlling the condensing equipment based on
wet-bulb temperature or humidity.
When a bulb thermometer is wrapped with a water-soaked towel, it reads the temperature
as a wet bulb. The wet-bulb temperature would be the same as the ambient air
temperature if the relative humidity was 100%. Due to evaporative cooling, the wet-bulb
temperature is lower than the dry-bulb temperature when the humidity is lower. The wet-
bulb temperature is the lowest temperature that can be obtained by evaporating water
under present environmental circumstances.

4. The condenser pressure should be kept as low as feasible in order to save energy. As
the compressor's braking horsepower per tonne of refrigeration required decreases, the
return is perceived as enhanced compressor efficiency. At lower discharge pressures,
screw compressors run more efficiently. Lowering discharge pressure, on the other hand,
might have an impact on other parts of the facility, so keep an eye out for potential side
effects. Liquid injection and evaporator system defrost are two areas that should be
scrutinized.
Ambient circumstances must also be considered. It will be more difficult to maintain a
lower discharge pressure just by turning on all of the equipment and allowing it to operate
at 100% if it is really hot outdoors. Instead, get the wet-bulb temperature by combining
humidity and temperature.
The lowest discharge pressure feasible for evaporative condensers is equal to the
saturated liquid pressure at the wet-bulb temperature plus the condenser approach
temperature. It is feasible to establish the minimum condensing pressure using a wet bulb
and utilize that number as the condenser pressure's floating setpoint. The amount of labor
required by the compressor can be minimized by combining floating suction with floating
discharge pressure control, lowering energy consumption.
Load control is the third and most important way to boost efficiency. Depending on the
time of day, electric companies charge varying fees. It is feasible to shift load needs to
off-peak hours when kilowatt use is less expensive, thanks to contemporary control
technologies. During these periods, the cooling is turned down to a considerably lower

5. setpoint, and the facility relies on a battery or a flywheel for power. This permits the
system to be turned off during the day when energy costs are minimal.
Many power providers base their tariffs on both demand and the time of day. The highest
15 minutes of average usage determines the demand fee. Processors can track energy
use in different regions of the plant to counteract this problem. When kilowatt use rises,
the load is reduced to lower total demand. For example, if a cold-storage facility has six
evaporators working and is already at capacity, four of them can be turned off to minimize
demand. Peak demand costs can be considerably reduced using this method.
3. Assuring Food Safety
Monitoring the temperature within the cold storage is one approach to assure food safety.
Many advanced control systems can run facilities automatically and without human
interaction. The controls issue automatic alarms and have pre-programmed reactions to
any problems that develop. More Industrial Internet of Things (IIOT) and web-based
interfaces for remote monitoring are becoming accessible, and enhanced analytics make
condition monitoring more straightforward.
4. Following FSMA and HACCP Requirements
The Food Safety Modernization Act (FSMA) and Hazard Analysis and Critical Control
Point (HACCP) rules, notable to the requirements for automatic reporting, can be made
easier to comply with automated monitoring. Data may be recorded and saved for a longer
amount of time in modern control systems. Facilities can prepare reports for subsequent
examination using past data. During third-party audits, the reports can also be utilized for
food process, verification, and safety evaluations.
5. Switching to More Environmentally Friendly Refrigerants
This lends itself nicely to the shift to more climate-friendly refrigerants, continuing the
thread of continuous monitoring and automated reactions. Having safety and
dependability helps with the shift to alternative refrigerants, whether the system is using
ammonia, propane, carbon dioxide, or low GWP HFOs. Advanced algorithms allow the
system to be adjusted to the new refrigerants while being as energy efficient as possible,
as well as leak detection for staff safety.

6. An industrial refrigeration business will benefit from combining all of these mentioned
strategies. Alaqua is a USA based processing equipment such as crystallizer, distillation
equipment, heat exchanger, solvent recovery, spray dryer, and evaporators supplier in
USA that supplies them worldwide. They also offer various services for processing
equipment. Contact them today to know more about the processing equipment and their
services!