On June 11, 2024, Embraco, a leading provider of advanced refrigeration solutions within the Nidec Global Appliance portfolio, joined forces with Structural Concepts, a renowned manufacturer of temperature-controlled display cases, to present a groundbreaking case study at the ATMOsphere America Summit 2024. This collaboration highlighted the successful migration of Structural Concepts' entire product line to the use of natural refrigerant R290 combined with variable-speed technology, resulting in impressive energy savings of up to 53%.
During this initiative, Structural Concepts underwent a significant transformation by shifting its range of refrigerated food displays from traditional fixed-speed compressors using HFO refrigerants (R449A and R513A) to Embraco UFMFT condensing units equipped with dual voltage variable-speed compressors running on R290. To thoroughly evaluate the performance of this change, both companies conducted extensive monitoring across various applications, comparing the outcomes against the previous configurations.
One notable example was a small under-counter application featuring a single refrigeration circuit utilizing less than 150 grams of R290. This setup achieved a remarkable 53% reduction in energy consumption and a 55% cut in Total Equivalent Warming Impact (TEWI). Another case involved an upright grab-and-go display case with two refrigeration circuits (each using less than 150 grams of R290), which showed an 11% decrease in energy usage and a 17% drop in TEWI. Additionally, further testing was performed on a horizontal display case measuring 1.2 x 2.4 meters (4x8 feet) with two refrigeration circuits powered by R290 and variable-speed compressors operating independently. Following the installation of the newly launched Embraco Sync Controller, specifically designed to manage multiple refrigeration circuits simultaneously, the system achieved a 12% energy saving.
"The Embraco Sync Controller is part of our Sync it All portfolio, which includes the Embraco AIR fan, the YouControl development interface, and Embraco variable-speed compressors," explained Johari Gregorio, Nidec Global Appliance's Application Engineer for North America. "These tests clearly demonstrated how the Sync Controller enhances energy efficiency and maintains stable temperatures by working seamlessly with our variable-speed compressors."
This migration not only brought environmental benefits but also streamlined Structural Concepts' production processes. Previously managing 38 different compressor models due to varying refrigerants and voltage requirements, they now rely on just two Embraco condensing unit models fitted with dual voltage R290 variable-speed compressors capable of supporting their full range of refrigerated merchandisers. "The UFMFT model stands out with its compact size—only about 25 centimeters tall—and features a cleverly designed drain pan connected via pipes to multiple pans, ensuring efficient condensate management with a substantial water holding capacity of approximately 4.9 liters (1.3 gallons) per pan," added Gregorio.
Compliance with upcoming regulatory standards was another key advantage. As the U.S. Environmental Protection Agency (EPA) sets a cap on the Global Warming Potential (GWP) of commercial food refrigeration equipment at 150 starting January 2025, transitioning to R290 ensures Structural Concepts meets these criteria ahead of schedule. Moreover, these innovations prepare them for future Department of Energy regulations while contributing to significant reductions in CO2 emissions—estimated to lower TEWI by 33% on average.
"This move toward variable-speed technology and natural refrigerants has empowered us to deliver more efficient and eco-friendly products, aligning perfectly with consumer expectations and industry trends," remarked Rob Dody, Structural Concepts' Senior Engineering Manager.
"Suppliers like Structural Concepts can maximize efficiency by purchasing fully assembled condensing units ready for integration into their designs rather than sourcing individual components," noted Gregorio. "This approach saves valuable time and resources, enabling businesses to concentrate on what truly matters—their core products."
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