The results shared here are part of a detailed case study presented during the ATMOsphere America Summit by both Embraco, a leading global provider of advanced refrigeration technology under the Nidec Global Appliance umbrella, and Structural Concepts, a prominent manufacturer specializing in temperature-controlled display cases. This presentation took place on June 11, 2024.
During the summit, the duo highlighted a groundbreaking initiative where Structural Concepts successfully migrated its entire product lineup to utilize natural refrigerant R290 alongside variable-speed technology. This shift not only achieved impressive energy savings of up to 53% but also set a benchmark for sustainability within the industry.
Collaboratively, Structural Concepts revamped its range of refrigerated food display units. They transitioned from traditional fixed-speed compressors, which relied on HFO refrigerants like R449A and R513A, to Embraco UFMFT condensing units. These units are equipped with dual-voltage variable-speed compressors and use eco-friendly R290 refrigerant. To showcase the efficacy of this change, both companies closely tracked the performance across two distinct applications—a smaller food display with a single compressor and a larger upright grab-and-go display case featuring two compressors.
In the first application, an under-counter unit with just one refrigeration circuit utilizing less than 150 grams of R290, there was a remarkable 53% reduction in energy usage and a 55% cut in Total Equivalent Warming Impact (TEWI). Meanwhile, the second application, a larger upright grab-and-go display case with two refrigeration circuits (each using less than 150 grams of R290), saw a 11% decrease in energy consumption and a 17% drop in TEWI. Further testing on a 1,20 x 2,40 meter horizontal display case—designed with two refrigeration circuits and R290 variable-speed compressors working independently—showcased additional efficiency gains. Following the installation of the newly launched Embraco Sync Controller, which manages multiple refrigeration circuits seamlessly, the system achieved a 12% energy saving.
“The Embraco Sync Controller is just one of the innovative solutions within our Sync it All portfolio,†explained Johari Gregorio, Nidec Global Appliance's Application Engineer for North America. “This controller significantly enhances energy efficiency and temperature stability, especially when paired with our variable-speed compressors.â€
This migration also streamlined Structural Concepts' manufacturing processes. Previously, they had to manage a complex inventory of 38 different compressor models due to varying refrigerants and voltages. Now, they rely on just two Embraco condensing unit models, each equipped with dual-voltage R290 variable-speed compressors capable of supporting their full range of refrigerated merchandisers. As Rob Dody, Structural’s Senior Engineering Manager, noted, “This simplification not only reduces complexity but also increases flexibility in our production lines.â€
Additionally, the UFMFT model boasts compact dimensions—just about 25 centimeters tall (10 inches)—allowing it to fit easily into any cabinet setup while maximizing product visibility. Its innovative drain pan design, featuring interconnected piping, ensures optimal condensate management across multiple units, with each pan holding approximately 4.9 liters (1.3 gallons).
Beyond operational efficiencies, this transition aligns perfectly with upcoming regulatory standards. The U.S. Environmental Protection Agency (EPA) plans to limit the Global Warming Potential (GWP) of commercial food refrigeration equipment to 150 starting in January 2025. By adopting R290, Structural Concepts complies with these regulations ahead of schedule. Moreover, the energy-efficient nature of these systems prepares them for future Department of Energy guidelines while reducing carbon emissions by an estimated 33% across their entire portfolio, a significant step towards decarbonization.
“This move to variable-speed technology and natural refrigerants empowers us to deliver products that are not only more efficient but also environmentally responsible, meeting both customer expectations and market demands,†said Dody.
For refrigeration equipment manufacturers like Structural Concepts, purchasing fully assembled condensing units offers substantial benefits. Embraco’s solution reduces assembly time and effort, enabling partners to concentrate on their core competencies—the creation of high-quality food displays. As Gregorio emphasized, “By focusing on what they do best, our clients can enhance their competitive edge.â€
Overall, this initiative marks a pivotal moment in sustainable innovation within the food retail sector, setting a precedent for others to follow.
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