Optimization of Existing Facilities
More Power, Lower Electricity Costs
The most efficient refrigeration system is often the one you already own—if it’s set up correctly. Many industrial refrigeration systems operate far below their optimal performance: Incorrect settings, outdated controls, or dirty heat exchangers drive up your electricity bill unnecessarily. cold.world ENGINEERING analyzes your existing system, uncovers hidden savings potential, and makes your equipment ready for the future—without the need for immediate replacement.
Renovate Instead of Investing: When Is It Worth It to Make Improvements?
It is not always necessary or cost-effective to completely replace the refrigeration system. A technical upgrade (retrofit) is the right approach when:
- Energy costs are skyrocketing: Outdated components and poor control strategies are the most common causes of high electricity bills.
- Refrigerant Issues (F-Gases): Are you still using refrigerants such as R404A or R507A? The F-Gas Regulation is making these extremely expensive and scarce. We’ll evaluate options for converting to future-proof alternatives.
- Common Problems: Does the system break down frequently or fail to maintain the desired temperatures in the summer? This is often due to hydraulic issues or wear and tear, which we can fix.
Our Approach: Data-Driven Analysis Instead of Assumptions
We don’t just replace parts on a hunch. We measure and analyze.
1. Energy Inspection & Assessment We thoroughly examine the current condition of your system. This includes performance measurements, checks for overheating or undercooling, and an analysis of operating times.
2. Control Optimization: The greatest potential often lies in the control system (“software before hardware”). By adjusting the condensing and evaporating pressures (sliding control) or optimizing defrost cycles, it is often possible to save 15–20% in energy—without any structural modifications.
3. Technical Retrofit & Modification Where necessary, we replace components:
- Retrofitting variable-frequency drives (VFDs) on compressors and pumps for optimal part-load operation.
- Use of EC fans on condensers.
- Retrofitting a heat recovery system to make use of waste heat.
- Replacing old expansion valves with electronic fuel injectors.
The Problem with R404A / R507A (F-Gas Phase-Down)
Operators of older systems are under pressure. In some cases, high-GWP refrigerants may no longer be replenished during service work. We’ll give you honest advice:
- Drop-In / Retrofit: Can we convert the system to a more modern refrigerant (e.g., R449A or R513A)?
- Strategic Approach: If a retrofit is not technically feasible, we plan a phased transition to natural refrigerants (NH3, CO2, propane) to avoid stranded assets.
Frequently Asked Questions About Optimization
Will production have to be halted for the renovation? In most cases, no. We plan renovations and retrofits so that they take place while operations are ongoing or during non-production periods. For complex projects, we provide temporary mobile cooling units.
Are there any grants available for optimization? Yes! The BAFA (Federal Office for Economic Affairs and Export Control) provides substantial funding not only for new construction but also for the energy-efficiency upgrades of existing facilities and the use of measurement and control technology. We can assist you with the application process.
Schedule an Initial Consultation
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