Future-Proof Refrigeration: How a Leading Food Manufacturer Embraced Low-GWP Solutions
Climalife UK
Introduction
With tightening F-Gas regulations and businesses seeking to further reduce their environmental footprint whilst improving their site facilities, a Lincolnshire-based food manufacturer sought a refrigeration upgrade that would support long-term performance and sustainability.
Coretemp was selected to provide a solution that met both current requirements and future regulatory demands when seeking to upgrade its cold store systems. The food manufacturer worked collaboratively with the Coretemp team who in turn, worked closely with Climalife to find solutions that combined compliance, efficiency and long-term reliability. R-454A and advanced safety technology was thus chosen, offering efficiency, compliance and resilience for years to come.
Expertise driving sustainable solutions
Coretemp Refrigeration Ltd is an air conditioning and refrigeration contractor specialising in light industrial refrigeration. Based in Huntingdon, the company employs nine staff, including seven engineers. They pride themselves on delivering practical, honest solutions with a strong focus on energy efficiency and system longevity.
Refrigerant decisions for the long term
The existing system at the food manufacturing site operates R-449A (GWP 1397) condensing units across 10-15 temperature-controlled rooms, each requiring different temperatures depending on the application. The food manufacturer approached Coretemp when exploring solutions to future-proof their refrigeration facilities.
Coretemp, consulted with the Climalife team who reiterated the ongoing changes to F-Gas legislation, including the quota reduction system and its potential impact on refrigerant supply. This backed up the need to select a compliant and long-term refrigerant solution.
After discussions and a joint visit, a number of refrigerant options were considered with some being deemed as unsuitable or cost prohibitive for the application. The agreed approach was to replace an existing cold store system with a low-GWP refrigerant offering both performance and longevity.
R-454A was selected for its low GWP (239) and best fit for the application. Being an A2L refrigerant, compliance with EN378 and DSEAR regulations was carefully checked by Coretemp to ensure safety and adherence to UK standards. If customers need guidance in this area, Climalife can assist.
Engineering for Performance and Peace of Mind
The new installation features Bitzer Ecolite condensing units paired with Güntner evaporators and RDM controls. As part of the design support, Climalife provided detailed advice on pipe sizing.
System operating conditions:
- Evaporating temperature: -1°C
- Condensing temperature: 45°C
- Cooling capacity: 42 kW
Enhanced system control with Carel technology
Climalife’s Head of UK Sales, Dave Richards assisted by carrying out valve selections and providing full specifications on the electronic expansion valve system. Each system uses:
- Carel E2V electronic expansion valves
- Carel EVD evolution valve drivers
- Carel UltraCap backup modules
The UltraCaps play a crucial role in system safety, in the event of a power failure, they hold an electrical charge long enough to allow the valves to wind fully shut, reducing the risk of refrigerant migration or leakage. This added layer of protection supports both system integrity and environmental safety.
Advanced leak detection with Bacharach
Although the refrigerant charge was within the limits defined in EN378, the food manufacturer and Coretemp Refrigeration opted to install leak detection as an added safety measure, reflecting the site’s strong safety culture. The project included Bacharach MGS‑450 fixed gas detectors installed in key areas.
Smooth delivery through collaboration
The installation process was smooth and efficient, thanks to the strong collaboration between Coretemp and Climalife. The on-site engineering team placed strong trust in Coretemp’s expertise and decision-making, ensuring confident decision making at every stage. Compliance checks were carried out meticulously ensuring that the system was both safe and fully aligned with UK standards and regulations.
Future ready solutions
The system has only been operational for a short period, but early feedback has been very positive. The cost impact was minimal versus running the R-449A system, with the only notable addition being the leak detection system. Improvements in energy efficiency are anticipated as the new equipment settles into operation.
This project demonstrates how collaboration and forward-thinking choices can deliver sustainable, efficient refrigeration solutions. Combining the use of R-454A with technologies such as Carel EVD controls and Bacharach leak detection confidently supports today’s environmental and legislative challenges. The selection of R-454A and the integration of advanced safety and control technologies ensure the client is well-positioned to meet future regulatory requirements and achieve long-term operational success.
“Having worked with Dave Richards for a number of years, Coretemp engaged Dave and the team at Climalife to support our project from the outset. Their early involvement and clear guidance on current and future F-Gas regulations helped deliver a successful phasedown and selection of a future-proof refrigerant solution.
Climalife also supplied the refrigerant, control components, and leak detection system, backing this up with practical, knowledgeable support throughout. Their approachable team added real value at every stage of the project, and we would be very happy to recommend their services”. Mark Bushell, Senior Engineer Coretemp Refrigeration Ltd
By combining technical expertise, regulatory foresight, and innovative safety measures, this project sets a benchmark for sustainable and efficient refrigeration solutions in the food manufacturing industry.
