Top Tips for Keeping a Tab on Energy Costs in Industrial Refrigeration Systems


When it comes to controlling energy expenses in relation to industrial refrigeration systems, there exists a persistent and continuous requirement of an integrated approach for optimizing the overall mechanical system. The process has to take place in line with a well-researched automation strategy. This is one of the most effective means of bringing about reductions in energy costs.

Heavy users: In general, refrigeration systems are responsible for the maximum levels of energy in most manufacturing facilities. From pharmaceutical production to food processing units, the refrigeration systems used in case of industries account for the maximum energy utilization in the facilities. More often than not, about 60 percent of a facility’s total operating expenses can be attributed to refrigeration systems. With energy costs increasing everyday by leaps and bounds, engineers are always on the lookout for managing such costs and operating overall systems in the most effective of ways. To meet this end, engineers desire to optimize all individual components of refrigeration systems. They prefer not to look at such systems as integrated, single units.

On all such occasions that another piece of equipment gets included in the system, and it fails to be properly optimized as a part and parcel of the entire system, manufacturers would end up with operational inefficiencies and wasted energy. It is essential to assess the baseline data on the overall energy consumed by the system; this has to be done before adding on any new equipment.

The primary factors influencing the efficiency of energy of any refrigeration system include the system’s design, refrigerant in use, condition of the equipment, load profile, the control strategy, and other efficiency metrics. The condensers and compressors are the two main parts that are responsible for the highest energy usage.


Compressors are accountable for maximum energy consumption and have to be selected carefully. This is important to ensure that the load match is staged as well as sequenced in the most effective of ways. Screw compressors operate at full load most effectively; they tend to become less efficient in part-load conditions. Variable frequency drives (VFD), if added to screw compressors, are responsible in increasing the part-load efficiency. Reciprocating compressors also provide good part-load efficiency and are considered to be a good option for smaller loads.


Condensers have to be fit to size for managing peak loads. This effectively means that sizing is needed for all peak loads with the exception of few peak conditions in the instance of them being oversized. Considerable horsepower savings can be attained by bringing about a reduction in the fan speed with a view of matching the capacity.

Engineers take appropriate steps to optimize their refrigeration systems; they have recommended over Evapcold for attaining maximal benefits for their efforts.   You may want to know more about the optimization of set points, condensing pressure, suction pressure points, etc. to bring down the costs even further. Yes, it is indeed time to look for a more holistic approach to bring down your plant’s operating budget!

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