Optimization of existing systems: more power, lower electricity costs
The most efficient refrigeration system is often the one you already have – if it is set up correctly. Many industrial refrigeration systems run far below their optimum: incorrect parameters, outdated controls or dirty heat exchangers drive up electricity bills unnecessarily. cold.world ENGINEERING analyzes your existing system, uncovers hidden savings potential and makes your technology fit for the future – without the need for an immediate new build.
Renovating instead of investing: When is optimization worthwhile?
A complete replacement of the refrigeration technology is not always necessary or economically viable. Technical optimization (retrofit) is the right way to go if:
- Energy costs are exploding: Outdated components and poor control strategies are the most common causes of high electricity bills.
- Refrigerant problems (F-gases): Are you still using refrigerants such as R404A or R507A? These are becoming extremely expensive and scarce due to the F-Gas Regulation. We check conversion options for future-proof alternatives.
- Frequent faults: Does your system often break down or fail to maintain temperatures in summer? This is often due to hydraulic faults or wear and tear, which we can rectify.
Our approach: Data-based analysis instead of guesswork
We do not simply replace parts on suspicion. We measure and analyze.
1. energy inspection & inventory We thoroughly check the current condition of your system. This includes performance measurements, checking overheating/subcooling and analyzing running times.
2. control optimization The greatest potential often lies in the control system (“software before hardware”). By adjusting the condensation and evaporation pressure (sliding control) or optimizing defrost cycles, it is often possible to save 15-20 % energy – without any structural changes.
3. technical retrofit & conversion Where necessary, we replace components:
- Retrofitting frequency converters (FC) on compressors and pumps for partial load operation.
- Use of EC fans on condensers.
- Retrofitting a heat recovery system to make waste heat usable.
- Replacement of old expansion valves with electronic injection valves.
The problem with R404A / R507A (F-Gases Phase-Down)
Operators of older systems are under pressure. In some cases, high-GWP refrigerants may no longer be refilled during service work. We give you honest advice:
- Drop-in / retrofit: Can we convert the system to a more modern refrigerant (e.g. R449A or R513A)?
- Strategic replacement: If a retrofit is not technically feasible, we plan a gradual transition to natural refrigerants (NH3, CO2, propane) in order to avoid investment ruins.
Frequently asked questions about optimization
Does production have to be stopped for the conversion? Not in most cases. We plan conversions and retrofits so that they take place during ongoing operations or during non-production times. For complex interventions, we provide mobile rental refrigeration.
Are there subsidies for optimization? Yes! The BAFA (Federal Office of Economics and Export Control) not only provides massive funding for new buildings, but also for the energy optimization of existing systems and the use of measurement and control technology. We support you with the application process.