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Distribution centre energy saving

Newport, South Wales. UK: Norbert Dentressangle has installed an energy saving cold storage cooling system from Star Refrigeration at its distribution centre near Newport, South Wales.

Star designed and installed the refrigeration plant for a cold store at the Norbert Dentressangle site, which will deliver an estimated 40% saving in annual energy costs.  The ammonia system replaced an existing plant that operated on R22 – an ozone-depleting refrigerant currently being phased out by EU legislation.

Star designed and installed the refrigeration plant for a cold store at the Norbert Dentressangle

Norbert Dentressangle wanted an energy efficient cooling system to serve a frozen food cold store.  The facility has a throughput of over 600 frozen pallets each week, with products from the region’s food manufacturers being distributed to retailers and food service outlets across the UK.

Star supplied a bespoke ammonia refrigeration plant for the Norbert Dentressangle cold store, which houses six insulated chambers with automated doors and has total volume of around 31,500 cubic metres.

Star designed, built, installed and commissioned a single stage pumped circulation ammonia refrigeration plant for Norbert Dentressangle.  With a total capacity of around 450kW, the plant delivers cooling via 10 evaporators to maintain cold store temperature at minus 22 degrees centigrade.

James Ward, Star Refrigeration’s director of sales – food market, says: “As part of the R22 phase out and a drive to reduce energy consumption across the Norbert Dentressangle estate, our system is designed for optimum operating efficiency at an affordable running cost.  As well as operating on natural refrigerant ammonia, the plant incorporates energy saving equipment and controls to provide significant electrical savings when compared to standard pumped circulation designs.”

“We are confident that as well as having a refrigeration plant that complies with environmental legislation, Norbert Dentressangle will save around 40% off its annual energy bill thanks to the design of the system.”

Located in a new plant room adjacent to the cold store, the refrigeration plant features two screw compressors and one reciprocating compressor to give highly efficient part load operation.  The ammonia system also includes surge drum, open flash intercooler and one common evaporative condenser.  Star’s Telstar PLC computerised control and management system ensures optimum performance and energy efficiency, with HMI touch screen interface.

Star’s energy efficient plant design package for Norbert Dentressangle includes defrost on demand, floating head suction pressure, an Aether condenser fan inverter controller and intelligent compressor controls.   Star also improved the design of the existing cold store evaporators with graduated fin spacing to allow longer operation between defrosts.