Structural’s food display reaches up to 53% energy savings with Embraco R290 variable-speed condensing units

The findings outlined below stem from a detailed case study presented at the ATMOsphere America Summit 2024 by Embraco, a leading global provider of refrigeration technology under the Nidec Global Appliance umbrella, in collaboration with Structural Concepts, a renowned manufacturer specializing in temperature-controlled display cases.

June 11, 2024 – Embraco, alongside its partner Structural Concepts, showcased a groundbreaking case study at the ATMOsphere America Summit 2024. This presentation highlighted the successful migration of Structural Concepts' entire product lineup to natural refrigerant R290 and variable-speed technology. The transition resulted in significant energy savings, reaching up to 53% compared to conventional systems.

In this collaborative effort, Structural Concepts made a pivotal shift in its refrigerated food display portfolio. They moved away from fixed-speed compressors utilizing HFO refrigerants (R449A and R513A) to adopting Embraco UFMFT condensing units equipped with dual-voltage variable-speed compressors, all powered by the eco-friendly R290 natural refrigerant. To evaluate the migration's impact, both companies closely monitored the performance across two distinct applications: a smaller food display featuring a single compressor and a larger upright grab-and-go display case with two compressors.

The initial application, an under-counter unit with a single refrigeration circuit using less than 150 grams of R290, demonstrated a remarkable 53% reduction in energy consumption and a 55% cut in Total Equivalent Warming Impact (TEWI). Moving forward, the second application—an upright grab-and-go display case with two refrigeration circuits, each containing less than 150 grams of R290—achieved an 11% decrease in energy use and a 17% reduction in TEWI. Furthermore, additional testing conducted on a horizontal display case measuring 1.20 x 2.40 meters (4x8 feet), equipped with two independent refrigeration circuits, yielded a 12% energy savings post-installation of the newly launched Embraco Sync Controller. Designed to synchronize multiple refrigeration circuits, this controller proved instrumental in optimizing both energy efficiency and temperature stability.

"The Embraco Sync Controller is just one piece of the Sync it All portfolio, which includes the Embraco AIR fan, the YouControl interface, and our Embraco variable-speed compressors," explained Johari Gregorio, Nidec Global Appliance’s Application Engineer for North America. "These tests clearly show how the Sync Controller enhances energy efficiency while maintaining precise temperature control, particularly when paired with our variable-speed compressors."

This transition not only bolstered energy efficiency but also streamlined Structural Concepts' production processes. According to Rob Dody, the company's Senior Engineering Manager, "Previously, we had to manage 38 different compressor models due to varying refrigerants and voltage requirements. Now, thanks to Embraco's UFMFT condensing units, we can rely on just two versatile models, equipped with dual-voltage R290 variable-speed compressors, to cover our entire range of refrigerated merchandisers."

Johari Gregorio added, "The compact design of the UFMFT model, standing at approximately 25 centimeters tall (10 inches), ensures compatibility with all cabinet sizes, maximizing product display space. Its innovative drain pan system, connected via piping to multiple units, offers an impressive water-holding capacity of around 4.9 liters (1.3 gallons) per pan."

Structural Concepts' decision to adopt R290 aligns perfectly with impending regulatory changes. As the U.S. Environmental Protection Agency (EPA) enforces stricter limits on the Global Warming Potential (GWP) of commercial food refrigeration equipment—capping it at 150 starting January 2025—the shift to R290 ensures compliance well ahead of schedule. Moreover, the energy-efficient nature of these systems positions Structural Concepts favorably for future Department of Energy regulations. The environmental benefits are equally profound; the overall migration is projected to reduce TEWI by 33% on average, translating into substantial reductions in CO2 emissions.

Rob Dody expressed his enthusiasm, stating, "Transitioning to variable-speed technology and natural refrigerants has empowered us to deliver products that are not only more efficient but also environmentally responsible, aligning with consumer expectations and industry trends."

"For food retail refrigeration manufacturers like Structural Concepts, purchasing complete condensing units ready for installation simplifies the process significantly," Johari Gregorio noted. "It saves time, reduces labor costs, and allows businesses to concentrate on what they do best—designing exceptional food displays."

This case study underscores the transformative potential of embracing advanced refrigeration technologies, paving the way for a more sustainable and competitive future in the food retail sector.

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